Numerical Simulation and Optimization Design of Particle Transport in 3D Printers Spiral Extrusion 3D Printers

Abstract

Abstract In response to the challenges of feed delay and inconsistent wire production in existing 3D printers, a novel 3D simulation model for spiral extrusion 3D printers was developed. This model incorporates the particle filling rate within the spiral groove as a critical evaluation criterion, establishing a correlation between the transport section parameters and the filling rate. The simulation software STAR-CCM+ was utilized for in-depth analysis, leading to structural optimizations based on various feeding mechanisms. The effects of different hopper models on feeding efficiency were investigated using the principles of the discrete element method. The findings indicate that the enhanced feed structure effectively addresses particle transportation issues within the printer. An increase in rotational speed is shown to improve the filling efficiency of the spiral groove, while simultaneously reducing the residence time of the particle material in the extruder, which in turn affects particle melting quality. By integrating the simulation data with experimental validation, an optimized printing structure was designed to fulfill the requirements of spiral extrusion printers.