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Numerical Simulation and Experimental Study of the Extrusion Process in Additive Manufacturing for High-Viscosity and

Dashun Zhang1, Shijun Ji1, Ji Zhao1

  • 1School of Mechanical and Aerospace Engineering, Jilin University, Changchun 130012, China.

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|February 27, 2026
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Summary

This study optimized additive manufacturing equipment for high-viscosity energetic materials, finding cylindrical screws and specific kneading/extrusion rates ensure stable filament formation and complex shape fabrication.

Keywords:
additive manufacturingexperimental verificationhigh viscosity and high solid contentnumerical simulation

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Chemical Engineering

Background:

  • Screw adhesion and nozzle clogging are common issues in additive manufacturing of high-viscosity, high-solid-content energetic materials.
  • These phenomena hinder the precise and safe fabrication of complex energetic material structures.

Purpose of the Study:

  • To investigate and mitigate screw adhesion and nozzle clogging in energetic material additive manufacturing.
  • To optimize equipment design for enhanced safety, precision, and adaptability in extreme conditions.
  • To achieve continuous and stable filament formation for complex-shaped energetic material charges.

Main Methods:

  • Combined numerical simulation and experimental validation were used to analyze energetic material extrusion.
  • Conical and cylindrical screws were designed and simulated to understand internal pressure and shear rate variations.
  • A Z-shaped stirring paddle kneading device and a dual-nozzle printing device with two-stage screws were developed and tested.
  • Extrusion experiments with polymer-bonded explosive (PBX) slurry were conducted to determine optimal kneading and extrusion rates.

Main Results:

  • Numerical simulations guided the design of printing equipment by analyzing pressure and shear rate patterns.
  • Experimental validation identified optimal matching relationships between kneading and extrusion rates for PBX slurry.
  • The cylindrical screw design with a 3mm clearance was found to be superior to the conical screw.
  • Optimal parameters include a 3-hour kneading process at 25 rpm for uniform slurry (70% solids), and extrusion with a 1.55 mm nozzle, 5 rpm horizontal screw, and 7 rpm vertical screw for "starved feeding".

Conclusions:

  • The optimized additive manufacturing equipment successfully produced complex-shaped PBX charges.
  • The findings confirm improved safety control, precision, and adaptability for energetic material additive manufacturing.
  • The study provides a validated design solution for overcoming common challenges in processing high-viscosity energetic materials.