A Process Parameter Design Method for Improving the Filament Diameter Accuracy of Extrusion 3D Printing

Process parameters have a significant impact on the filament diameter of extrusion 3D printing. To precisely control filament diameter, this paper proposes a novel method based on experiments to guide process parameter design. Additionally, an extrusion 3D printing device was developed, by which the influence of crucial process parameters and rheological properties on the diameter of printed filaments could be investigated experimentally and theoretically. Furthermore, poly (l-lactide-co-ε-caprolactone) (PLCL) was used as a case study to detail the design procedure of the proposed method. The printable range of the process parameters for PLCL was acquired, and a fitting surface for the experimental data was calculated to guide the process parameter design. According to the results of the experiment, by adjusting the process parameters, PLCL filaments with five different diameters of 120, 130, 140, 150, and 160 μm can be fabricated with a 100 μm nozzle. The deviations between the actual filament diameters and the desired diameter are less than 5 μm, which validates the reliability of the proposed method.