Development of a Pellet and Filament Form Integrated Multi-Material Additive Manufacturing Co-Extruder

Abstract There are two methods to 3D print a part using extrusion-based additive manufacturing technology namely filament-based and pellets/granules-based. Filament-based extrusion needed a wire form material called a filament, which is pushed by a motor and gear mechanism, into a heating zone. In the heating zone, it converts in semi-solid form and is extruded out of the nozzle to deposit in a layer-over-layer manner. This extrusion strategy needed a non-flexible filament, so it limits the variety of materials. Converting material into wire form also increases the cost of 3D printing. Pellet-based extrusion accepts the material in granules form. It is fed into the heating zone using an extrusion screw. This technology can accept a wide range of materials and eliminate the cost of producing filament. But pellet-based technology is still not being used on 3D printers, on the other hand, filament-based technology in the form of 3D printers is very popular in the market. So, in this study development of noble pellet and filament form integrated multi-material additive manufacturing co-extruder has been presented. The developed co-extruder is capable to accept material in filament form as well as pellet/granules form. This will help to 3D print a particular part with several materials. This hybrid form of the extruder is accommodating the features of both types of extrusion-based additive manufacturing. As per need, one can easily shift from filament extrusion to pellet/granules extrusion using this co-extruder.