Hybrid Extrusion

After conducting a literature review on current clay extrusion technology, I identified an opportunity for innovation in bringing the level of allowable overhangs in paste extrusion up to the standard of thermoplastic extrusion. This was currently impossible, because the support structures used in thermoplastic 3D printing are inadequate structurally and bond to the part when made in paste. I developed a rationale and scope for the project, communicated in a research defense to project stakeholders.

The solution I developed uses a custom paste extruder to create the part itself, and a dedicated thermoplastic extruder to create support structures. The paste extruder is a simple plunger design, chosen for it's volumetric consistency and simplicity, and is retrofitted onto a thermoplastic 3D printer. This research leverages the advances in thermoplastic 3D printing to make possible previously too complicated geometries for clay extrusion.

The design validated the feasibility of the system in addressing the core need, proving successful in adherence and bridging tests. Several areas for development and innovation were identified, and opportunities laid out for future work. The results were presented in a comprehensive research paper and presentation to stakeholders.