Nozzle clogging factors during fused filament fabrication of spherical particle filled polymers

Fused filament fabrication with reinforced or filled polymers provides improved material properties compared to ordinary feedstock. A current limitation of these materials is the occurrence of nozzle clogging at higher filler contents. In this work, an experiment is designed to identify the factors causing nozzle clogging. Glass sphere-filled polycarbonate is investigated by varying nozzle and filler diameters, the resin viscosity, the filler content, and the extrusion pressure. Equations identifying nozzle clogging and intermittent clogging conditions are provided. Based on these results, a model for the clogging of sphere-filled polymers is proposed. Last, a mathematical model is derived, which approximates the printability of filled polymers without the preparation of composites. This model is based on the nozzle geometry, the filler type and content, the resin viscosity, and the printer's maximum extrusion force.