<p>A screw-barrel system was designed and implemented, coupled with material extrusion. The aim was to integrate two methods: the direct extrusion of thermoplastic polymer pellets with material extrusion, to utilize various polymers in the form of pellets, especially high melt temperature ones, instead of traditional filaments. This addresses one of the significant challenges in filament preparation for various materials that are not readily available in the market or nearly impossible to fabricate (such as highly filled plastics). First, the screw-barrel mechanism was designed and manufactured as an extrusion system and was installed on additive manufacturing platform. Then screw-barrel assembly performance and factors influencing feed rate were evaluated. Subsequently, specimens were printed with polyether ether ketone (PEEK), an advanced plastic material known for its outstanding mechanical properties, high-temperature tolerance, and broad applications in various sectors, such as medical. In addition, the material was reinforced with 2.5% continuous glass fibers while printing, which presented a novel product. Upon comparing theoretical values with experimental data from the tensile testing, a notable observation emerged, in which by the inclusion of 2.5% glass fibers, there was an approximate 43% increase in the tensile strength of the material. Furthermore, SEM images provided visual evidence of satisfactory adhesion between layers and fibers.</p> Graphical abstract <p></p>