Structure Design of Helical Dual-Channel Nozzles for 3D Printers and Investigation of Part Mechanical Properties of Printed Parts

This paper overcomes the shortcomings of low mechanical properties for Fused Deposition Modeling (FDM). A dual-channel, single-nozzle print head with a helical mixing channel is designed to realize co-extrusion and in-situ mixing between pure ABS and fiber reinforced ABS. The finite element analysis characterizes the nozzle thermal field distribution and compares the tensile and compression stress strain behavior between pure ABS and composite materials. The thermal simulation validated the design feasibility to produce a steady thermal gradient. Mechanics Analysis according to materials’ characteristics showed the composite theoretical ultimate tensile strength is greater than pure ABS, furthermore, FEA results confirmed higher elastic modulus and stiffness for the composite with same loading. This result confirms that the coextrusion architecture is capable of supporting loads and provides an engineering solution to improve FDM’s strength properties.