MIE.01 – Spraying Systems Deformable Orifice Nozzle

The spray pattern and orifice diameter of conventional nozzles are rigid, fixed bodies, inherently limiting the adaptability for various applications within the spray nozzle industry. This inflexibility also creates a need to frequently replace nozzles as their orifices erode out of specification. These innate constraints result in a repetitive and tedious process of nozzle removal and reapplication to accommodate diverse line operations, reducing overall uptime and manufacturing productivity. In response to this challenge, Spraying Systems Company has tasked our team with the development of a novel deformable spraying solution. Our objective is to design and manufacture a versatile nozzle featuring an adjustable orifice capable of dynamically altering the spray pattern. Our proposed design aims to provide a substantial improvement by enabling in situ and adjustment of a nozzle during operation such that the spray pattern changes shape or angle by 10-20%.

Various methods of adjustment and ideas of actuation were researched and considered. Concepts from multiple of these were made into preliminary designs. Based on feasibility, cost, and many other factors, these were refined and iterated until a final prototype design was landed on. This design was then precisely 3D modeled using SolidWorks to fit Spraying System’s existing Veejet standardized nozzle system. Leveraging the characteristics of TPU-70A, known for its silicone-like properties and structural rigidity, the nozzle was 3D printed, ensuring it could withstand the operational pressure while maintaining good flexibility. Following assembly, testing was conducted at Spraying Systems using a proprietary test stand. Video of each test was taken and later analyzed using ImageJ software to determine the change of the spray pattern angle. This analysis determined a change in spray angle of over 20%, exceeding the desired outcome, and suggesting that this novel method of in situ nozzle adjustment may be applicable in industry given more research and refinement.