Design and Analysis of Fused Deposition Modeling 3d Printer Nozzle in Different Materials

Abstract

In Fused Deposition Modelling have led to the creation of inexpensive desktop based Rapid Prototypes such as the Replicating Rapid-Prototype (Rep Rap) allowing the individual the freedom to fabricate three dimensional parts of their own, however print resolutions of the parts are not on the same level as commercially based systems. It has been observed that adjusting the certain parameters on the polymer melt extruder such as the extruder nozzle diameter, nozzle angle, and liquefier length ultimately affects the extruded melt flow behaviour. These parameters are important factors to consider for an improved design. This thesis presents the results of the computational and experimental work that shows this effect taking the original specifications of the RepRap extruder and aims to show how reducing nozzle exit diameter and varying nozzle angle has resulting effects on pressure drop and the flow behaviour of the melt. The results show that optimization of the flow rate can have signification effects on the extruded melt and it also shows limitations on how small the nozzle exit diameter can be before the resulting pressure drop becomes too large such that the motor cannot provide enough torque to drive the flow. Ultimately, the proposed redesign suggests that the RepRap’s extruder with specific nozzle diameter and angle which will decrease the diameter of the extruded melt contributing to better resolutions.