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The RepRap 3D printer development project is a fast growing, open-hardware initiative relying on the input of hobbyist designers. One of its key components is the printer nozzle. The performance and reliability deficiencies of currently available nozzle designs are common topics in the RepRap community, and our own experience with a RepRap 3D printer has identified a need for improvement in a few particular areas. We set out to eliminate melt leakage, improve thermal isolation, and develop a more effective method of nozzle assembly attachment. Here, we review the issues, describe design efforts, and report results.

Offshore applications, which call for the largest and most powerful wind turbines, demand a higher standard of reliability and maintainability. Direct-drive permanent-magnet synchronous generators (DD-PMSGs) are increasingly being specified for these applications. The major shortcoming to traditional high-powered direct-drive generators is extraordinary size and mass leading to extraordinary cost. To generate higher powers at low rotational speeds, directdrive generators must either develop greater tangential stresses or be larger in diameter. For traditional air-cooled generators, higher power generally means a much larger diameter. Dramatic cost savings can be realised with the development of a more effective stator windings cooling system that puts further the limit on current density enabling the development of high-power direct-drive generators of substantially smaller diameters. This study presents a direct liquid cooling system design for an 8 MW outer-rotor DD-PMSG. The approach is new for wind turbine generators, so its impact on the thermal behaviour and reliability for the total electrical machine has been evaluated and reported here. Testing of a stator coil prototype (1/72nd of the complete stator) with internal cooling liquid flow is also reported to demonstrate the workability of the designed cooling solution.

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