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<p>This study presents the development of a novel filament coating setup to enhance the mechanical properties of polymer filaments used in Fused Filament Fabrication (FFF). The innovative setup was designed to apply a uniform coating onto the surface of the filaments, offering precise control over the thickness of the applied coating. To investigate the effect of different factors on the coating thickness, key parameters such as dwell time, nanoclay content, and the temperature of the nanoclay solution are varied. A full factorial design of experiments (DOE) was implemented to study the influence of these parameters. The experimental results revealed that an increase in both dwell time and nanoclay content led to a corresponding increase in the coating thickness. In contrast, higher temperatures of the solution caused a reduction in the thickness of the applied layer. By optimizing these parameters, the coating thickness was controlled within a range of 20–50&#xa0;µm. This research provides a comprehensive framework for developing automated coating systems for FFF filaments, addressing the growing need for enhanced material properties in additive manufacturing applications.</p>

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Design and Development of Automated Filament Coating System for Fused Filament Fabrication

  • 期刊论文

  • 发表日期：

    2026年4月8日

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  • Abhishek Patel,
  • Krishnanand,
  • Mohammad Taufik

摘要

This study presents the development of a novel filament coating setup to enhance the mechanical properties of polymer filaments used in Fused Filament Fabrication (FFF). The innovative setup was designed to apply a uniform coating onto the surface of the filaments, offering precise control over the thickness of the applied coating. To investigate the effect of different factors on the coating thickness, key parameters such as dwell time, nanoclay content, and the temperature of the nanoclay solution are varied. A full factorial design of experiments (DOE) was implemented to study the influence of these parameters. The experimental results revealed that an increase in both dwell time and nanoclay content led to a corresponding increase in the coating thickness. In contrast, higher temperatures of the solution caused a reduction in the thickness of the applied layer. By optimizing these parameters, the coating thickness was controlled within a range of 20–50 µm. This research provides a comprehensive framework for developing automated coating systems for FFF filaments, addressing the growing need for enhanced material properties in additive manufacturing applications.