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Related Experiment Video

Updated: Jun 25, 2026

Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding

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Design, Modeling, and Validation of a Compact, Energy-Efficient Mixing Screw for Sustainable Polymer Processing.

David O Kazmer¹, Stiven Kodra²

¹Department of Plastics Engineering, University of Massachusetts Lowell, Lowell, MA 01854, USA.

|January 25, 2025

Summary

This study introduces a novel mixing screw for energy-efficient extrusion, achieving higher throughput and better thermal homogeneity. The innovative design offers improved performance for sustainable polymer processing applications.

Keywords:

dispersive mixing distributive mixing modeling plasticating screw extrusion simulation thermal mixing validation

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Area of Science:

Polymer processing engineering
Materials science and engineering
Mechanical engineering

Background:

Single-screw extrusion is a widely used polymer processing technique.
Energy efficiency and material homogeneity are critical for sustainable polymer processing.
Traditional screws often have long length-to-diameter ratios, limiting their application in compact systems.

Purpose of the Study:

To design, model, and validate a novel mixing screw for energy-efficient single-screw extrusion.
To enhance plastication and thermal homogeneity using a short length-to-diameter (L/D) ratio screw with specialized features.
To evaluate the performance of the mixing screw for processing high-impact polystyrene (HIPS) and recycled polypropylene (rPP).

Main Methods:

Design of a mixing screw with L/D ratio of 8:1, double flights, variable pitch, and counter-rotating mixing slots.
Non-isothermal, non-Newtonian simulations to model thermal and flow behavior.
Experimental validation using a 20 mm pilot-scale extruder at varying screw speeds and barrel temperatures.

Main Results:

Demonstrated a strong linear dependence of mass output on screw speed, with maximum throughputs of 0.58 kg/h (HIPS) and 0.74 kg/h (rPP) at 40 RPM.
Achieved specific energy consumption (SEC) of 0.264 kWh/kg (HIPS) and 0.344 kWh/kg (rPP), with efficiencies of 31.5% and 56.5%, respectively.
Showcased improved energy efficiency and reduced residence time distribution compared to traditional screws.

Conclusions:

The novel mixing screw design is effective for energy-efficient single-screw extrusion.
The screw's features enhance plastication and thermal homogeneity, suitable for processing HIPS and rPP.
Potential applications include compact extrusion systems, 3D printing, and sustainable polymer/bioplastics processing.