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<p>While screw extrusion-based 3D printing is widely used, its industrial scalability remains constrained by inconsistent plasticization and thermal heterogeneity. To mitigate these issues, a novel screw design (i.e., field-synergy torsion element) was proposed, leveraging the polymeric field synergy principle to optimize melt preparation. Through high-fidelity numerical simulations, the influence of torsion element arrangement and spatial density was systematically evaluated in terms of melting length, plasticization efficiency, and temperature uniformity. The results revealed that the torsion-spiral flow generated by these elements markedly enhanced radial mass transfer, strengthening field synergy between velocity and temperature gradients. By strategically optimizing the density and distribution of torsion elements, an improvement of 16.7% in plasticization efficiency was achieved, along with a reduction in exit-temperature fluctuations by 54.5%. This work presents a fundamentally new screw configuration that advances melt quality and process stability in extrusion-based 3D printing, offering a scalable pathway toward high-performance industrial applications.</p> Graphical abstract <p></p>

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Design and thermal-plasticization optimization of a novel screw for high-performance extrusion 3D printing

  • 期刊论文

  • 发表日期：

    2025年12月18日

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  • Zexin Wang,
  • Shilin Wang,
  • Jiawei Zhu,
  • Xiang Cheng,
  • Weimin Yang,
  • Ranran Jian

摘要

While screw extrusion-based 3D printing is widely used, its industrial scalability remains constrained by inconsistent plasticization and thermal heterogeneity. To mitigate these issues, a novel screw design (i.e., field-synergy torsion element) was proposed, leveraging the polymeric field synergy principle to optimize melt preparation. Through high-fidelity numerical simulations, the influence of torsion element arrangement and spatial density was systematically evaluated in terms of melting length, plasticization efficiency, and temperature uniformity. The results revealed that the torsion-spiral flow generated by these elements markedly enhanced radial mass transfer, strengthening field synergy between velocity and temperature gradients. By strategically optimizing the density and distribution of torsion elements, an improvement of 16.7% in plasticization efficiency was achieved, along with a reduction in exit-temperature fluctuations by 54.5%. This work presents a fundamentally new screw configuration that advances melt quality and process stability in extrusion-based 3D printing, offering a scalable pathway toward high-performance industrial applications.

Graphical abstract