Introduction

The growing use of 3D printing in both industrial and academic settings has increased the demand for high-quality polymeric filament [1]. Producing filament using a commercial extruder from pellets can reduce costs and improve material customization. However, ensuring dimensional stability and consistent quality remains a key challenge. This work focuses on the setup and optimization of a commercial single-screw extruder for the production of filament suitable for fused deposition modeling (FDM) 3D printers.

Methods

A commercial tabletop extruder was adapted and calibrated to process thermoplastic pellets into filament. Key operational parameters, including extrusion temperature, screw speed, and cooling rate, were systematically varied. A real-time diameter monitoring system was implemented to assess filament uniformity during extrusion. The influence of each parameter on filament diameter and surface finish was analyzed. Post-extrusion, the filament was evaluated using calipers and visual inspection to ensure dimensional consistency.

Results

This research found that maintaining a stable extrusion temperature and carefully controlling the extrusion rate and cooling environment are critical for achieving consistent filament diameter. The optimal combination of parameters led to the production of filament with a diameter close to 1.75 mm. The real-time implemented monitoring system proved effective in identifying anomalies during the manufacturing process, allowing for rapid control adjustments.

Conclusions

The successful optimization of the extrusion process enables the reliable production of polymeric filament from raw pellets using a commercial extruder. The methodology ensures dimensional stability and quality suitable for 3D printing applications. Future work will focus on extending the approach to recycled plastic to promote sustainability in additive manufacturing.