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<p>Additive manufacturing by material extrusion (MEX) has gained relevance due to its versatility in processing polymers; however, the development of extrusion-based systems with portability, modularity, and advanced monitoring remains limited. Most existing machines rely on fixed architectures with restricted customization, sensor integration, and maintenance, limiting their applicability in research and specialized applications. This study proposes a modular additive manufacturing machine equipped with a miniaturized single-screw extrusion head. The system combines compactness (410 × 410 × 650&#xa0;mm, ~ 12&#xa0;kg) with a modular barrel design that facilitates maintenance, screw configuration adjustments, and integration of melt temperature and pressure sensors. Analytical modeling was conducted to estimate key process parameters, followed by experimental validation using polypropylene micro-pellets. Extrusion performance was characterized through output flow rate, residence time, die swell, and deposition trials, complemented by mechanical testing of printed specimens. The extrusion head provided stable material flow, producing filaments with good surface quality and no critical defects. Minimum residence times of ~ 1–2&#xa0;min and die swell indices of 1.5–1.8 were consistent with ranges reported for single-screw extrusion and MEX, despite deviations from analytical predictions. Deposition tests confirmed the strong effect of platform speed on bead geometry, while tensile specimens exhibited stiffness (~ 1400&#xa0;MPa), strength (~ 27&#xa0;MPa), and ductility (~ 122%), aligning well with literature values for polypropylene processed through MEX.</p>

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Design and extrusion evaluation of a modular additive manufacturing machine with a head assisted by a single screw

  • 期刊论文

  • 发表日期：

    2025年10月13日

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  • Dávila Moreira Lopes Silva,
  • Joaquim Manoel Justino Netto,
  • Marcelo Aparecido Chinelatto,
  • Jorge Lino Alves,
  • Zilda Castro Silveira

摘要

Additive manufacturing by material extrusion (MEX) has gained relevance due to its versatility in processing polymers; however, the development of extrusion-based systems with portability, modularity, and advanced monitoring remains limited. Most existing machines rely on fixed architectures with restricted customization, sensor integration, and maintenance, limiting their applicability in research and specialized applications. This study proposes a modular additive manufacturing machine equipped with a miniaturized single-screw extrusion head. The system combines compactness (410 × 410 × 650 mm, ~ 12 kg) with a modular barrel design that facilitates maintenance, screw configuration adjustments, and integration of melt temperature and pressure sensors. Analytical modeling was conducted to estimate key process parameters, followed by experimental validation using polypropylene micro-pellets. Extrusion performance was characterized through output flow rate, residence time, die swell, and deposition trials, complemented by mechanical testing of printed specimens. The extrusion head provided stable material flow, producing filaments with good surface quality and no critical defects. Minimum residence times of ~ 1–2 min and die swell indices of 1.5–1.8 were consistent with ranges reported for single-screw extrusion and MEX, despite deviations from analytical predictions. Deposition tests confirmed the strong effect of platform speed on bead geometry, while tensile specimens exhibited stiffness (~ 1400 MPa), strength (~ 27 MPa), and ductility (~ 122%), aligning well with literature values for polypropylene processed through MEX.