We demonstrate a novel Fused Filament Fabrication (FFF) nozzle design to enable measurements of in-situ conditions inside FFF nozzles, which is critical to ensuring that the polymer extrudate is flowing at appropriate temperature and flow rate during the part build process. Testing was performed with ABS filament using a modified Monoprice Maker Select 3D printer. In-situ measurements using the printer’s default temperature control settings showed an 11 °C decrease in temperature and significant fluctuation in pressure during printing as well as fluctuations while idle of ± 2 °C and ±14 kPa. These deviations were eliminated at lower flow rates with a properly calibrated proportional–integral–derivative (PID) system. At the highest tested flow rates, decreases in melt temperature as high as 6.5 °C were observed, even with a properly calibrated PID, providing critical insight into the significance of flow rate and PID calibration on actual polymer melt temperature inside the FFF nozzle. Pressure readings ranging from 140 to 6900 kPa were measured over a range of filament feed rates and corresponding extrusion flow rates. In-situ pressure measurements were higher than theoretical predictions using a power-law fluid model, suggesting that the assumptions used for theoretical calculations may not be completely capturing the dynamics in the FFF liquefier. Our nozzle prototype succeeded in measuring the internal conditions of FFF nozzles, thereby providing a number of important insights into the printing process which are vital for monitoring and improving FFF printed parts.
