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ABSTRACT
This study describes the redesign and development of a plastic extrusion machine that will be able to continuously produce 5 (mm) diameter plastic filament. A solid thermoplastic material is melted, pushed through an extrusion die with the required cross-section, and cooled in a water bath to perform the polymer conversion process known as extrusion. The temperature in each zone of the extruder barrel needs to be accurately controlled in order to create plastic filament products of high quality. The plastic extrusion system's temperature varies greatly and is susceptible to several disruptions. Since the system is typically nonlinear and has several stages and is connected with other systems, managing the temperature is a difficult task. This study aims to provide an illustration of the plastic extrusion machine's design process, covering the design of the cooling, driving, and controlling systems. This study also provides an illustration of the design process from problem statement formulation to prototype testing. The goal of the project is to develop and build a low-cost, safe, and user-friendly plastic extrusion machine that can be used to produce continuous plastic filaments, which are a necessary component of 3D printing technology. From this point on, the project's significance increases because it advances humankind's prosperity and growth. The project's goals are to design with the environment, high performance, safety, affordability, and assembly in mind. Redesign restrictions, cost, availability, manufacturing feasibility, sustainability, and ethical considerations are the project's limitations.
