A prototype single-screw filament extruder was developed for cost-effective production of 1.75mm diameter thermoplastic filament, intended for fused deposition modelling (FDM), or fused filament fabrication (FFF) MEX-AM systems. The system successfully achieved polymer filament extrusion, however, its compact design, constrained to a single heating zone, imposed limitations on throughput, and evenly ramped melt zone. This small-scale extruder was fabricated within a tight budget of INR Rs. 22,000 (USD $260), significantly lower than commercially available equipment. Future development will incorporate an inline filament diameter sensor to implement closed-loop control for filament dimensional consistency, and improve extruder nozzle design.
