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3D Printer Extruder Calibration Guide

Under- and over-extrusion FDM print quality issues are well-known in 3D printing. Calibration of the extruder, which involves calculating E-steps and tuning the extrusion multiplier, is essential. In this guide, we will walk through the full process for Marlin and Klipper firmware-based extrusion calibration. Also, we will dig into the filament flow rate, or extrusion multiplier, setting.

How to optimize the process of polymer extrusion

Extrusion is a process widely used in the polymer processing industry. It involves pushing material through a die with a specific cross-sectional shape, resulting in products like profiles, thin sheets, films and tubes. However, the shape of the final product (the so-called extrudate) is highly influenced by a phenomenon called swell. Ph.D. candidate Michelle Spanjaards has developed a numerical model that reduces this problem. She will defend her thesis at the department of Mechanical Engineering on Friday 21 of January.

Precision is extremely important for extrudates, to make sure they have exactly the desired dimensions. However, extrudates tend to expand once the fluid leaves the die, due to internal stresses in the material, leading to suboptimal products.

Usually, this problem is solved using an experimental trial-and-error approach, a process that is unsustainable because it produces unnecessary material waste. It is also time-consuming and thus inefficient and costly.

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