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<p>One of the key advancements in extrusion-based additive manufacturing (AM) is the development of screw-assisted 3D printheads, which provide a promising alternative to traditional filament-fed 3D printers, particularly for composite and blended polymer systems. These printheads enable direct deposition from pelletized feedstock, higher printing speeds, and enhanced material processing, allowing for greater control over material properties. This study presents a hybrid 1D-3D modeling approach to characterize melt flow behavior in a customized 3D printhead based on a co-rotating twin-screw extruder (Co-TSE), designed to integrate polymer compounding and deposition into a single processing route. The model combines simplified 1D calculations with localized computational fluid dynamics (CFD) analysis, focusing on the melt flow along a modular, self-wiping twin-screw with an <i>L/D</i> ratio of 11 and a 12&#xa0;mm outer diameter. Unlike standard industrial extruders, this miniaturized Co-TSE operates under unique conditions, including a limited screw speed range (up to 100&#xa0;rpm) and a low feed rate (up to 40&#xa0;g/h) in a starve-fed processing mode. By integrating 1D and 3D modeling, this approach effectively evaluates key processing parameters such as screw filling ratio, pressure distribution, velocity fields, local shear rates, shear-induced heat generation, and residence times. The 1D model provides a global flow description, while 3D simulations offer detailed insights into fully filled regions. The results demonstrate that the proposed model effectively assesses the thermomechanical environment within the printhead under varying operating conditions, making it a valuable tool for predicting processing limits and mixing efficiency.</p>

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Melt flow behavior in a 3D printhead based on a miniaturized co-rotating twin-screw extruder: a combined 1D-3D modeling approach

  • 期刊论文

  • 发表日期：

    2025年8月20日

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  • André Luiz Grando Santos,
  • Joaquim Manoel Justino Netto,
  • Zilda de Castro Silveira,
  • Alessandra de Almeida Lucas

摘要

One of the key advancements in extrusion-based additive manufacturing (AM) is the development of screw-assisted 3D printheads, which provide a promising alternative to traditional filament-fed 3D printers, particularly for composite and blended polymer systems. These printheads enable direct deposition from pelletized feedstock, higher printing speeds, and enhanced material processing, allowing for greater control over material properties. This study presents a hybrid 1D-3D modeling approach to characterize melt flow behavior in a customized 3D printhead based on a co-rotating twin-screw extruder (Co-TSE), designed to integrate polymer compounding and deposition into a single processing route. The model combines simplified 1D calculations with localized computational fluid dynamics (CFD) analysis, focusing on the melt flow along a modular, self-wiping twin-screw with an L/D ratio of 11 and a 12 mm outer diameter. Unlike standard industrial extruders, this miniaturized Co-TSE operates under unique conditions, including a limited screw speed range (up to 100 rpm) and a low feed rate (up to 40 g/h) in a starve-fed processing mode. By integrating 1D and 3D modeling, this approach effectively evaluates key processing parameters such as screw filling ratio, pressure distribution, velocity fields, local shear rates, shear-induced heat generation, and residence times. The 1D model provides a global flow description, while 3D simulations offer detailed insights into fully filled regions. The results demonstrate that the proposed model effectively assesses the thermomechanical environment within the printhead under varying operating conditions, making it a valuable tool for predicting processing limits and mixing efficiency.