Optimization of a Desktop Single-Screw Extrusion System for the Fabrication of PLA and Composite Filaments


DURSUN B., ŞAHİN A.

3rd International Conference on Artificial Intelligence, Computer, Data Sciences, and Applications, ACDSA 2026, Boracay Island, Filipinler, 5 - 07 Şubat 2026, (Tam Metin Bildiri) identifier identifier

  • Yayın Türü: Bildiri / Tam Metin Bildiri
  • Doi Numarası: 10.1109/acdsa67686.2026.11468225
  • Basıldığı Şehir: Boracay Island
  • Basıldığı Ülke: Filipinler
  • Anahtar Kelimeler: 3D printer filament production, Filament extruder optimization, Filament winder, Single-screw extruder
  • Trakya Üniversitesi Adresli: Evet

Özet

Additive manufacturing (3D printing) allows for low-waste production of parts with complex geometry; additive manufacturing also provides a viable method for on-demand production of customized products at the small scale. Additive manufacturing is viewed as one of the key enablers of Industry 4.0 and can contribute to better resource efficiency and sustainability in a number of industries such as health care, manufacturing and education. The quality of parts produced by fused deposition modeling fused filament fabrication (FFF), or fused deposition modeling (FDM) processes is dependent on the thermoplastic filament used to produce them. The physical properties of these filaments will significantly affect the print quality and mechanical integrity of the final product, thereby affecting their functionality. Producing good quality pure and composite filaments for use in FDM and/or FFF printing requires very precise control over numerous factors that influence one another; e.g., extruder temperature, screw rotation speed, pull rate, and cool rate. The present study used a commercially available single screw filament extruder (desktop) that had been modified to achieve better filament dimensional stability and better overall process consistency than the original machine. Modifications made to enhance filament dimension stability were; additional thermal insulation, use of reverse screw action, variable speed filament winding, in line filament diameter measurement system, and an active air cooling module. Using this improved configuration, the modified extruder produced both PLA and composite filaments having consistent diameters through out the filament length which was further validated with 3D printing test results. Therefore, the modification demonstrated reliable performance for producing filaments on a small scale (laboratory), and was useful for experimental development of special formulations of composite filaments.