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<p>Achieving an optimal balance between strength and flexibility in 3D-printed components remains a significant challenge, primarily due to material constraints in fused deposition modelling (FDM). Traditional FDM systems face difficulties when processing flexible materials like thermoplastic polyurethane (TPU), owing to filament buckling and high melt viscosity. To address these limitations, we developed a novel pellet-based co-extrusion additive manufacturing system capable of simultaneously extruding multiple materials. This system eliminates the reliance on pre-fabricated filaments and allows for the direct processing of both rigid and flexible thermoplastics, enabling customized mechanical performance within a single print. The study details the system’s hardware design, control architecture, process parameters, and mechanical testing of printed parts. Experimental results demonstrate that co-extruded PLA/TPU specimens achieve up to 302.80% elongation and 71 Shore D hardness, effectively bridging the mechanical gap between the base materials. Additionally, the process shows promise in improving surface finish. These findings underline the potential of the proposed co-extrusion system for fabricating parts with tunable mechanical properties, particularly suited for applications in biomedical devices, energy-absorbing components, and functionally graded materials.</p>

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Hybrid Pellet–Filament Co-extrusion for Customizing Flexibility and Strength in 3D-Printed Parts

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • Krishnanand,
  • Mohammad Taufik

摘要

Achieving an optimal balance between strength and flexibility in 3D-printed components remains a significant challenge, primarily due to material constraints in fused deposition modelling (FDM). Traditional FDM systems face difficulties when processing flexible materials like thermoplastic polyurethane (TPU), owing to filament buckling and high melt viscosity. To address these limitations, we developed a novel pellet-based co-extrusion additive manufacturing system capable of simultaneously extruding multiple materials. This system eliminates the reliance on pre-fabricated filaments and allows for the direct processing of both rigid and flexible thermoplastics, enabling customized mechanical performance within a single print. The study details the system’s hardware design, control architecture, process parameters, and mechanical testing of printed parts. Experimental results demonstrate that co-extruded PLA/TPU specimens achieve up to 302.80% elongation and 71 Shore D hardness, effectively bridging the mechanical gap between the base materials. Additionally, the process shows promise in improving surface finish. These findings underline the potential of the proposed co-extrusion system for fabricating parts with tunable mechanical properties, particularly suited for applications in biomedical devices, energy-absorbing components, and functionally graded materials.