Design and optimization of a novel extruder for 3D printer

Unlike traditional production tools, 3D printers create new objects by bonding layer upon layer until the desired shape has been achieved. There are more than twenty different types of printers, each using different technology. Among them, material extrusion is the most commonly used technology. In this study, the problems experienced in 3D printers using the material extrusion method were evaluated. Each production problem identified in the study was presented with detailed visuals, comprehensive information given about the causes of the problem, and solution advice suggested. The findings show that a significant amount of the production problems are related to the extruder system of 3D printers. For the optimization of the extruder, studies were carried out on nozzle, heat barrier, heater block, and cooler. To determine the flow behavior of the filament in the nozzle, Non – Newtonian flow analyses were carried out. The findings showed that nozzle diameter, nozzle angle, and the temperature of the filament in the nozzle are essential parameters in extruder design. Also nozzle temperatures are important for melting the filament in the desired time. It has been determined that the filament cannot be melted homogeneously at low nozzle temperatures. In line with the results obtained from the analyses, each extruder element was optimized, and a novel extruder was designed.