Industrial 3D printing
Stable processes despite abrasive filaments

Traditional solutions reach their limits

Mach-3D attempted to tackle the wear problem when printing abrasive materials using steel nozzles and ruby nozzles. However, neither approach provided a stable solution for continuous industrial use. With the steel nozzles, wear occurred during prolonged use, which affected print quality. Although ruby nozzles offered high wear resistance, they were more sensitive to mechanical stress. “For day-to-day operations, this meant additional maintenance work and, in some cases, unplanned downtime,” said Deickmann. It was therefore crucial to find a nozzle that not only lasts longer but also delivers consistent results.

DIANOZ restores process stability

The switch to a stable solution was achieved with Gühring’s DIANOZ diamond nozzle. What makes this nozzle so special is that the DIANOZ features a polycrystalline diamond (PCD) tip with a significantly higher hardness than brass or hardened steel, ensuring that the geometry and exit diameter remain stable even with abrasive filaments. The filament channel is friction-optimised and diamond-reinforced in the tapered section, to minimise wear and flow disturbances. Due to diamond’s high thermal conductivity, the actual nozzle temperature largely corresponds to the setpoint temperature, resulting in reproducible thermal conditions in the melt zone.

For Mach-3D, the benefits are evident in operation: “For us, the greatest advantage lies in the combination of high wear resistance, process reliability and consistent print quality,” says Erik Dieckmann. DIANOZ finally provides him with the reliability he had been seeking. “It was clear even after the first print tests that the nozzle had been developed for industrial use,” reports Dieckmann. He was particularly impressed by the combination of high-quality workmanship, technical design for abrasive materials and Gühring’s experience as a machining specialist.

Consistent quality over long runtime

The benefits are particularly evident during long-term use. Whilst the print pattern changes with conventional nozzles, DIANOZ remains stable. “Even after processing abrasive materials, we could not detect any significant changes in terms of print pattern, material flow or component quality,” confirms Dieckmann. This stability improves reproducibility. Dimensional accuracy and surface quality remain constant, regardless of runtime. At the same time, maintenance requirements are reduced. “We have been able to significantly reduce the effort involved in inspection, maintenance and nozzle replacement,” explains Dieckmann.  The machines can run for longer periods without intervention, making production planning easier.

Partnership rather than a supplier relationship

Mach-3D now uses the diamond nozzle as standard in its own production. “A close technological partnership has developed from what was once a traditional supplier relationship,” says Dieckmann. The director particularly values the fact that Gühring combines two crucial factors: outstanding product quality and decades of experience in the field of high-wear-resistant precision tools. “Whilst many suppliers come exclusively from the 3D printing sector, Gühring brings extensive expertise from the fields of machining and materials technology,” notes Dieckmann. “This expertise is directly reflected in the level of performance of the DIANOZ nozzles.”

The collaboration is now leading to a OEM partnership. Mach-3D will use DIANOZ as standard in its new large-format printers. “For our new machine, it was clear that we wanted to offer our customers a tried-and-tested solution right from the start, including for the printer nozzle,” says Dieckmann, explaining the decision. DIANOZ meets the industry’s high requirements, and in combination with Mach-3D’s large-format printers, this creates a seamlessly integrated system for users.

“Our customers benefit from greater process reliability and improved predictability,” explains Dieckmann. The partnership between Gühring and Mach-3D thus demonstrates how additive manufacturing can be industrialised – through components that deliver in operation and through collaboration that extends beyond the products themselves.