SAMPE Journal - July/August 2022 - 28
FEATURE
Z-PINNING ADDITIVE
MANUFACTURING
Design of a Penetrating Deposition Nozzle for
Z-Pinning Additive Manufacturing
Brenin Bales1, Tyler Smith2
, Seokpum Kim2
1University of Tennessee, Knoxville, TN
2
, Vlastimil Kunc1,2
and Chad Duty1,2
Manufacturing Demonstration Facility Oak Ridge National Laboratory (ORNL), Oak Ridge, TN
Email: BBales@utk.edu
ABSTRACT
Fused Filament Fabrication is an Additive Manufacturing method where a thermoplastic filament is deposited
layer-by-layer to create a three-dimensional part. The printed structures often demonstrate a high degree of
mechanical anisotropy, leading to a drop in material strength when comparing structures along the disposition
path (X and Y-Axis) to the build direction (Z-Axis). To reduce the mechanical isotropy, a z-pinning process was
developed which deposited continuous pins in the build direction. This process demonstrated significant gains
in inter-layer strength and toughness, especially for fiber-reinforced materials. However, the deposition of pins
also created flaws in the structures that increased in severity and frequency as the pins grew in length and
diameter. To mitigate these flaws, a penetrating nozzle has been proposed, in which a fine-tipped extrusion
nozzle extends into the pin cavity and simultaneously extrudes z-pins as it retracts. By extending the extruder
nozzle to a length that would permit it to penetrate the pin cavity heat loss through the nozzle, and therefor
filament cooling, is going to become a major issue. To investigate the thermal properties of the penetrating
nozzle, multiple finite element models were analyzed. The finite element analysis was conducted with a stock
nozzle and 50.8 mm material nozzles extensions with two common extruder materials. The finite element
analysis demonstrated that a 304 stainless-steel nozzle could be extended to a maximum length of 0.917 mm,
which would allow the nozzle to penetrate 3 layers during the pinning process. Creating a brass penetrating
nozzle would in turn, allow the penetrating nozzle to be extended to 2.205 mm, letting the nozzle to penetrate
8 layers into the pin cavity.
28 | SAMPE JOURNAL | JULY AUGUST 2022
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SAMPE Journal - July/August 2022
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