Effective, versatile and inexpensive extruder system for direct ink writing of high-viscosity pastes

Abstract We offer the possibility of implementing a lab made extruder for direct ink writing (DIW) into a conventional fused deposition modelling (FDM) 3D printer. The ink extruder was designed to comply with various requirements including the possibility of using multiple syringe volumes, ease of assembly, compatibility with numerous commercial FDM printers, ink retraction and ink flow control, and the ability to extrude inks with a wide range of viscosities (ink yield stresses from 135–1100 Pa). The load in the extruder was attained by combining a stepper motor and a gear reduction system. The reduction system was connected to a trapezoidal threaded spindle through a rigid coupler. The movement of the spindle was transmitted to the plunger of a syringe that contained the ink (with volumes ranging from 3–30 mL), by means of a linear guide system. Most of the extruder parts were printed with the same FDM printer to which the DIW extruder ended attached to. The DIW extruder wiring connections were simply made by using the E-axis connectors available in the FDM printer. Modifications of the FDM printer software required for the correct control of the DIW extruder were also relatively simple, avoiding firmware modification. This simplicity made the two DIW and FDM heads easily interchangeable, thus amplifying the functionality of a conventional FDM printer. The cost of this new DIW extruder is approx. 100€.