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All the current air nozzle designs have the air assist enter radially, causing the air to basically make a 90 degree turn inside the nozzle and creating a very turbid flow. Would it be more efficient to have the air assist enter the nozzle axially, pointed down slightly, creating a downward spiral of air? Would this create a more defined stream of air that would help to keep the beam path to the material clear of smoke?

The air that comes out of my nozzle is anything but weak. It's probably not ideal and may benefit from what you suggested, but that'd make it harder to make.