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Design Innovation Paper

Design of an Innovative Three-Dimensional Print Head Based on Twin-Screw Extrusion

[+] Author and Article Information
Joaquim M. Justino Netto

Department of Mechanical Engineering,
São Carlos School of Engineering,
University of São Paulo,
São Carlos 13566-890, São Paulo, Brazil
e-mail: joaquim.netto@usp.br

Zilda de C. Silveira

Professor
Department of Mechanical Engineering,
São Carlos School of Engineering,
University of São Paulo,
São Carlos 13566-890, São Paulo, Brazil
e-mail: silveira@sc.usp.br

Contributed by the Design Innovation and Devices of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received March 13, 2018; final manuscript received August 2, 2018; published online September 18, 2018. Assoc. Editor: David Myszka.

J. Mech. Des 140(12), 125002 (Sep 18, 2018) (6 pages) Paper No: MD-18-1213; doi: 10.1115/1.4041175 History: Received March 13, 2018; Revised August 02, 2018

This paper presents the embodiment design of an interchangeable print head based on twin-screw extrusion, specially developed to allow in-process multimaterial mixing and direct deposition of the product to structure three-dimensional (3D) parts. The print head focus on research applications with middle-end 3D printers. Commercial extrusion-based 3D printers have limited applicability due to the scarce variety of plastic filaments available. In that context, one important trend for the advance of additive manufacturing (AM) is the design of systems capable of using alternative material types in different states. The systematic process is presented as a case study and brings together concepts from mechanical design and polymer processing. The main contribution of this paper is to provide general guidelines to be used on similar projects, in view of the crescent demand for more adequate and flexible additive processes.

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References

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Figures

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Fig. 1

Concept of the experimental 3D printing platform with the print head based on twin-screw extrusion in detail showing its mains components

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Fig. 2

Geometric parameters defining the fully wiped and offset profiles for the co-rotating twin-screw

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Fig. 3

Design process proposed for the print head based on twin-screw extrusion

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Fig. 4

Resulting embodiment design of the extrusion set

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Fig. 5

(a) Torque rheometer and (b) opened chamber displaying the roller blades

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Fig. 6

Rheogram with the resistive torque recorded over time for three samples of material: pure ABS, ABS + 5 wt% alumina and ABS + 20 wt% SEBS

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Fig. 7

Three-dimensional printed mock-up showing (a) the complete assembly of the print head, in partial section and (b) the screws removed from the barrel

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