In this study, a granular feeding nozzle for Fused Deposition Modeling (FDM)-based 3D printers was designed an‎d developed. The main objective was to reduce material costs, improve recyclability, an‎d enhance energy efficiency in additive manufacturing. For this purpose, an extrusion system consisting of a screw, barrel, heating block, feeding hopper, an‎d temperature control unit was designed an‎d fabricated. Using polylactic acid (PLA) granules as the base material, test specimens were printed, an‎d their mechanical an‎d physical, properties were compared with those produced by filament-based extruders. The experimental results indicated that the mechanical performance of the samples printed using the granular extruder—such as tensile strength, Young’s modulus, an‎d elongation at break—was comparable to that of filament-based prints. From an economic an‎d energy analysis perspective, eliminating the melt-spinning process required for filament production significantly reduced the total production cost an‎d energy consumption. Moreover, the direct use of granules allowed for multi-stage polymer recycling with lower thermal degradation compared to conventional processes. Overall, the results demonstrate that the granular extrusion system can serve as an economical, sustainable, an‎d energy-efficient alternative to filament-based nozzles in FDM 3D printing. Keywords: 3D printing, granular nozzle, polylactic acid (PLA), Fused Deposition Modeling (FDM), economic analysis, energy consumption, polymer recycling

حسين حسني , محمد قانع

مهدي حجازي , افسانه ولي پوري