Published Paper Details:

This project focuses on the thermal performance analysis and optimization of a 3D printing hot end, a critical component in Fused Deposition Modelling (FDM) systems. The objective is to enhance heat dissipation, improve temperature control, and study the influence of nozzle design and process parameters on material flow and print quality. Thermal simulations were carried out in ANSYS to analyse heat dissipation with and without active cooling mechanisms, such as fans and air ducts. The study also explores how changes in nozzle material and geometric characteristics, including the diameter-to-height (D/H) ratio, impact thermal resistance and flow uniformity. Process parameters such as extrusion temperature and cooling rate were examined to understand their effect on thermal gradients and energy efficiency. Actual 3D-printed parts were produced using the optimized parameters and nozzle designs to validate the simulation results and demonstrate significant improvements in surface finish, mechanical strength, and dimensional accuracy. The improvised hot end features enable faster and more reliable printing, with the capability to process high-performance thermoplastics