Changing print resolution on BaAM via selectable nozzles

Big Area Additive Manufacturing (BAAM) is an additive manufacturing (AM) technique that rapidly deposits polymer to fabricate large components. However, the increase in deposition rates leads to a decrease in resolution and a consequent decline in part surface finish. A novel technique has been developed where the nozzle diameter can be changed mid-print using a poppet nozzle selector. With this technique, a course resolution can be employed to rapidly fabricate the interior of a part, while a fine resolution can be used on the surface. This allows for improved surface quality and resolution without significantly increasing print time. This work will explain the development of the selectable nozzle and integration with the BAAM system to produce selective high-resolution surfaces on parts.