FDM print speed is bottlenecked by melt rate, and Thomas Sanladerer is attacking that constraint directly. He fabricated experimental nozzles via SLS printing in MS1 tool steel, then finished them on a lathe with a 0.4 mm tip bore. The internal geometries tested include a triple-split material path and several intrusion-based designs engineered to maximize polymer contact area inside the nozzle body.
Testing ran on a Prusa Core One with a dedicated pressure rig to identify the flowrate at which each nozzle starts to fail. The Fuge design came out on top. The catch: MS1 is tool steel, a poor material choice for a nozzle that needs thermal conductivity and wear characteristics suited to filament extrusion, so these results are geometry benchmarks, not production specs.
The value here is not the winner. It is the methodology. Sanladerer's pressure rig gives a reproducible way to compare nozzle geometries before committing to expensive materials or machining. The full video walks through each design's internal structure and failure behavior, which is worth watching if you are optimizing a high-speed toolhead or evaluating commercial high-flow nozzle claims.
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