A Review of Thermoplastic Filament Extruder Design and Fabrication Technologies

Abstract

Thermoplastic filament extrusion plays a crucial role in diverse fields, particularly in 3D printing and sustainable recycling. This review delves into the design and fabrication aspects of filament extruders, highlighting key functionalities and recent advancements. We explore essential components like screws, barrels, and dies, discussing their impact on material processing and filament quality. Different fabrication methods, including machining, 3D printing, and casting, are evaluated based on their advantages and limitations for various materials and complexity levels. The review further highlights recent innovations in modular components, integrated mixing systems, and advanced control systems. We also discuss the growing adoption of sustainable practices in extruder design and fabrication. Finally, the diverse applications of filament extruders are explored, covering 3D printing, filament recycling, composite material creation, and medical applications. We conclude by outlining emerging trends like multi-material printing, nanocomposites, and bio-based materials, emphasizing the future potential of this dynamic technology.