Design and analysis of low-cost twin-screw filament extruder

Amran, Ammar Syafi (2023) Design and analysis of low-cost twin-screw filament extruder. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

The filament extruder machine is intended to produce the filament for 3-D printers. A filament with a diameter of 1.75-2.00mm is required for the 3-D printer. To continuously fed into a 3D printer. To manufacture filament a screw extrusion process is used to heat polypropylene (PP) pellets and forced through a nozzle. The goals which are to design a twin-screw filament machine, analyse the screw designs and to create a mocked prototype of twin-screw filament extruder for better two material mixing during the extrusion process. Data collection and research information to study about the concept of the working system of twin-screw extruder machine. The design process covered all of the design method starts with design sketching, parametric design, morphological chart, configuration deisgn and design concept. The polymer flow analysis (CFD) were performed towards two types of twin-screw extruder which is counter-rotating twin-screw and co-rotating intermeshing twin-screw using polypropylene (PP) as a material subject to identify the behavior of the material when travels inside the extrusion compression zone. Fabrication of the twin-screw filament extruder consist several crucial such as, MIG welding, drilling, 3D printing etc. As a result the completed design of twin-screw filament extruder was analysed with fenite element analysis (FEA) as well as the extrusion screw analysed with (CFD) simulation to identify the best design that suitable for filament extrusion process. Hence, the mocked prototype of twin-screw filament extruder was fabricated completely during this project despite several parts and components needs to be customized to fit with all the other working components.

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