3D Printer Nozzle Seal for the Ultimaker S3/S5

Finding that the cost of Ultimaker printer nozzle seals were costly, I decided to model a cheaper alternative to create at home!

3D Printer/ Resin Printer

Silicon or Heat Resistant material (Able to be injected into the mold)

Injecting Mechanism

3D Design Software, I used Fusion 360

Use Fusion 360 to model the mold of the extruder seal. I found that it made it easier to design the seal itself and make it a negative inside a block, then proceed to add tolerances, attachments, and resolve design limitations. I tried to make it come out of the mold as easy as possible, so I changed a few of the dimensions of the Ultimaker extruder seal. These alterations include: A thicker base for a more robust product, relief holes near thin aspects to get the silicone to flow through, and slightly enlarged aspects of the part that holds the seal into the printer, I found that it helps to get it to fit tight, although it makes it a little harder to install the seal.

After prototyping with a cheaper method, like 3D printing, you can use a resin printer to print your mold. I chose resin printing because of the thin layer lines and high quality, aspects that are needed on this small design. In my process, I found that resin printing the seal model in flexible resin is helpful in analyzing your accuracy in the smaller details. Paying attention to the tiny details is the key to getting the best product.

Sand and debur the parts; figure out what works for you to make the mold fit well and work efficiently. I used a combination of wood and cardboard to distribute the pressure of a clamp throughout the mold. You never want too much pressure in one place when dealing with cured resin, as it cracks easily. Make an extruder seal!