Analyzing the Feeding Behaviour of MEX Extruder Heads

Abstract

This thesis analyzes feeding force in extrusion-based additive manufacturing using simulations and experiments. A finite element model in Ansys Polyflow simulated non-Newtonian, non-isothermal flow through an E3D V6 nozzle. The focus was on predicting feeding resistance rather than melt behavior. Two materials ABS and a 316L polymer composite were modeled using shear-dependent viscosity (Cross model) and temperature-dependent properties (Arrhenius law). Simulations ran at three nozzle temperatures with two wall conditions: full adhesion and temperature-dependent slip. Feeding forces were measured with a force sensor on a modified 3D printer. Results show that force depends on temperature, material, and velocity. Simulated trends matched experiments in shape and scale, suggesting the model reflects key influencing factors and can aid further simulation development.