Material extrusion (MatEx) is the one of the most widely utilized additive manufacturing (AM) methods. The key to high printing quality in MatEx lies in the synchronization between the fast motion system and the slow extrusion system. However, the synchronization is challenged by the slow response of the extrusion system. In MatEx, there are two main types of extrusion systems: Bowden and direct-drive (DD), based on different extruder-hot end arrangements. DD systems have the extruder installed directly above the hot end, providing a relatively fast extrusion response but adding more inertia to the print head. In contrast, Bowden systems position the extruder on the printer’s frame, feeding the filament to the hot end through a long Bowden tube. As a result, this setup leads to a sluggish extrusion response due to the elasticity of the long segment of filament but has a lower print head’s inertia, offering a higher positioning accuracy compared to the DD system. To leverage the advantages of both extrusion systems, this paper proposes a hybrid extrusion system design that combines a Bowden extruder with a low-mass DD extruder for filament feeding. To optimize the design and control of the extruder, a low-order model that characterizes the hybrid extruder dynamics is proposed. The model is used to design a feedforward (FF) controller that minimizes the force exerted by the DD extruder motor in the hybrid extruder while achieving the desired extrusion accuracy. The effectiveness of the proposed extruder and the FF controller is validated experimentally by demonstrating transient responses as fast as those of the standard DD extruder with up to 65% less force required from the DD extruder motor. Data collected from motor torque–mass specifications of three motor series from three different manufacturers indicate that the torque/force reduction could yield up to a 69% mass reduction in the motor used for the DD extruder, adding only 32.5% extra weight of the hot end to the print head. Hence it holds the potential to achieve the same extrusion accuracy as standard DD extruders while significantly reducing print head inertia, hence the resulting vibration of the printer, as demonstrated using a case study.
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