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<p>The high cost of 3D printing feedstock is primarily attributed to the conversion of raw polymers into filament, which also directly impacts the mechanical, optical, and structural integrity of printed components in the fused filament fabrication (FFF) process. To address this limitation, a novel oblique (semi-vertical) filament extrusion system was developed, offering an affordable and compact solution for producing customized filaments from virgin, composite, and recycled materials. The system occupies approximately 2&#xa0;m<sup>2</sup>, costs between USD 600–1000, and achieves filament diameter control within ± 1.71% to ± 5.8% deviation, depending on the material. Key extrusion parameters—nozzle diameter, outlet angle, screw pulse interval, puller motor speed, and nozzle temperature—were experimentally optimized using regression modeling, with a predictive error range of 1.71-6.48% for filament diameter. Mechanical testing of 3D printed specimens confirmed strong material performance, with ultimate tensile strengths of 53.84&#xa0;MPa (PLA), 29.15&#xa0;MPa (TPU), and 22.18&#xa0;MPa (PLA + TPU 50/50). The system also successfully processed recycled PLA and Nylon-12 powder, highlighting its material versatility and potential for circular manufacturing. Overall, this work demonstrates a scalable, low-cost, and sustainable filament fabrication method that enhances FFF capabilities for research, education, and small-scale industry.</p>

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Design and Development of Oblique Filament Making Machine for Fused Filament Fabrication 3D Printing Process

  • 期刊论文

  • 发表日期：

    2025年10月13日

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  • Krishnanand,
  • Shashank Kulshreshtha,
  • Mohammad Taufik

摘要

The high cost of 3D printing feedstock is primarily attributed to the conversion of raw polymers into filament, which also directly impacts the mechanical, optical, and structural integrity of printed components in the fused filament fabrication (FFF) process. To address this limitation, a novel oblique (semi-vertical) filament extrusion system was developed, offering an affordable and compact solution for producing customized filaments from virgin, composite, and recycled materials. The system occupies approximately 2 m2, costs between USD 600–1000, and achieves filament diameter control within ± 1.71% to ± 5.8% deviation, depending on the material. Key extrusion parameters—nozzle diameter, outlet angle, screw pulse interval, puller motor speed, and nozzle temperature—were experimentally optimized using regression modeling, with a predictive error range of 1.71-6.48% for filament diameter. Mechanical testing of 3D printed specimens confirmed strong material performance, with ultimate tensile strengths of 53.84 MPa (PLA), 29.15 MPa (TPU), and 22.18 MPa (PLA + TPU 50/50). The system also successfully processed recycled PLA and Nylon-12 powder, highlighting its material versatility and potential for circular manufacturing. Overall, this work demonstrates a scalable, low-cost, and sustainable filament fabrication method that enhances FFF capabilities for research, education, and small-scale industry.