How to Make a High Resolution NYLON, ABS and PLA Nozzle for a 3D Printer.

This instructable will detail how to make a high resolution NYLON, ABS and PLA nozzle for a 3D Printer.
For a complete description as to building the new 3D Printer that can print in NYLON, just visit the main instructable:

https://www.instructables.com/id/Combination-CNC-Machine-and-3D-Printer/

This design will make use of a little known source of super low cost 0.5mm nozzles available just about anywhere.  The simple everyday  “Pocket Oiler”.  You may already have one as these as sometimes they are given out as advertising gifts!
At least 4 different oilers show up on Amazon’s web site, like
http://www.amazon.com/Pocket-Oiler-Lightweight-Rust-Inhibitors/dp/B002RMCDHM/ref=sr_1_1?ie=UTF8&qid=1338424483&sr=8-1

I still thought that some of the Pocket Oilers listed at some sites were just a bit expensive even at $5.00 - $8.00 so shop around.
The modification can be a bit tedious, you may want to pick up more than one.

Step 1: Cold Rolling the Pocket Oiler Tip

Use of the pocket oiler tip assumes you have a hot-end heater block with 6mm or 1/4 28 female threads.  The two types of pocket oilers I've used, have what's known as an "NPT" type thread, or plumbing pipe thread that fits well into a 6mm threaded heater block.

This is more of a procedure rather than a step-by-step instructable, so let's get the tools and parts we need!
Tools and Parts:

As you can see from the photo, we'll need the following:
1. Variable Speed Drill
2. Needle Nose Pliers
3. 2 each sockets for from a socket wrench set. - 1/2 inch and your next largest socket
4. Some wire, preferably a hard nickle wire typically used in small heaters
5. Our pocket oiler tip
6. A couple drops of just about any oil, even some left over from the pocket oiler will do fine

Process:

The process is that we will place the sockets on the pliers to form a cylindrical die set.  We'll add a few drops of oil to both the oiler tip as well as the sockets.  We'll place the tip in a drill, a section of wire down the tip and then start the drills rotation to max speed.  We'll then place the hand die set close to where the tip meets the aluminum support.  While the drill spins, we'll apply a increasingly stronger pressure on the die set via our pliers.  Eventually, the die set will "pressure cut" through the needle and the die set will clamp the wire.  What remains is a cold rolled reduction of the inner diameter of the oiler tip that is the same as the diameter of the wire.

Items of note:
Read through the process to fully understand each portion.  I would suggest that you practice on a small nail as nails are made of soft metal and you should see the results of the die and pressure.
The most important point is consistency and patience.  It's important to maintain even a small pressure at all times.
Once you have the drill running and the die set pressing on the needle tip, the actual time may be as high as 10 min of pressure.
Don't hurry, or you'll fracture the walls of the needle. If the wire falls out of the tip, just release pressure, replace the wire and start again.  Once more....no hurry.  I've done this several times to build nozzles of different ID's.....resolution and it seems the longer it takes, the better the results.

A smaller inner diameter nozzle means a higher resolution 3D Print.  The 3D Print may take longer, but it's worth it if the part has a lot of detail.

Again, this tip is for NYLON, ABS and PLA plastics.
NYLON has some great properties for parts that ABS and PLA can not compete with.
To build a 3D Printer that can print NYLON, Check out the following instructable.

https://www.instructables.com/id/Combination-CNC-Machine-and-3D-Printer/