Material dispense tips and methods for manufacturing the same

A method of forming an outlet hole in a material dispense tip suitable for low volume material dispensing operations, the dispense tip having an elongated neck and an elongated hole in the neck extending from an input end of the neck through an output end of the neck, comprising:

• positioning the output end of the neck including the hole in a region proximal to a die surface, wherein a surface of the output end of the neck abuts the die surface;
• inserting a punch into the hole at the input end of the neck, the hole including an inner taper between the input end of the neck and the output end of the neck;
• and
• applying an external force to a surface of the inner taper in the neck to cause the output end of the neck to deform under compression by the die surface, to reduce the diameter of the hole extending through the output end of the neck at the output end of the neck from a first diameter to a second diameter that is less than the first diameter, wherein the hole at the input end of the neck has a third diameter that is maintained in response to applying the external force to the neck, wherein the punch and the die surface each avoids direct contact with an inner wall of the hole at a position of the hole directly adjacent a narrowest portion of the inner taper to the output end of the neck at any time of deformation during which the diameter of the hole is reduced from the first diameter to the second diameter at the end of the deformation, and wherein the hole at the output end of the neck is unobstructed at the any time of deformation.