Parameter Optimization in FDM Filament Fabrication via Single Screw Extruder

The presence of polymer material filaments plays a crucial role in the realm of 3D printing. These filaments are utilized in 3D printing to create prototype products efficiently and cost-effectively. However, ensuring the production of high-quality prototype products necessitates the use of superior filaments characterized by consistent diameter and a round cross-section. Filaments are typically manufactured through an extrusion process using either a single screw extruder or a twin extruder. In this research, a DIY single-screw extruder was developed specifically for filament production. The main objective of this study is to generate quality filaments by optimizing the extruder parameters for various polymer materials. Three different polymers; Ethylene-vinyl Acetate (EVA), Polypropylene (PP), and Acrylonitrile Butadiene Styrene (ABS) were employed in this study. The research aimed to assess the melt flow index (MFI) to demonstrate viscous behavior and establish the ideal parameters for each material in the extrusion process. A total of 27 EVA material filament samples, 26 PP filament samples, and 26 ABS filament samples were successfully produced. Through analysis, optimal settings were identified for EVA, PP, and ABS filaments, resulting in high-quality production. The recommended parameters for producing quality EVA filaments included a temperature of 160°C, screw speed of 400 rpm, and take-up speed of 400 rpm. For PP filaments, the optimal settings comprised a temperature of 230°C, screw speed of 700 rpm, and take-up speed of 250 rpm. Lastly, ABS filament production was optimized with a temperature of 210°C, screw speed of 300 rpm, and take-up speed of 100 rpm. This project's outcomes are anticipated to have significant implications for future advancements in filament manufacturing processes.