The development of the MiniXtruder: a low-cost laboratory scale filament extruder with reduced internal dead volume for 3D Printing

OBJECTIVES: To develop a simple small-footprint, single-screw Hot Melt Extrusion device that can combine with existing laboratory equipment to facilitate rapid generation of 3D-printable HME filaments and benchtop quantities of 3D-printed filament for scale-up processes. METHODS: Design and development of the low-cost device which we call the MiniXtruder was carried out in silico and was manufactured using conventional laboratory tools, machining and 3D printing. To compare its capability, identical filament was produced on a commercial twin-screw extruder and compared with filament from the MiniXtruder. Extrudates from plain-PCL/PCL-caffeine loaded pellets were analysed by TGA, DSC and SEM. 3D printing of the was carried out on a MakerBot Replicator 2X Desktop 3D-printer. KEY FINDINGS: Realisation of the MiniXtruder as a small footprint/low-cost HME device that can produce 3D printable filaments. Different materials can be used with the device, resulting in facile extrudate production. The MiniXtruder shows versatility and decreased time/material consumption with low internal volumes and replicable filament production. CONCLUSION: The MiniXtruder’s potential to produce 3D-printable filament has shown that it is suitable for use in a laboratory setting and that it can replicate the production of 3D-printable filament from more expensive extruders whilst minimising the internal dead volume.