Mathematical Modeling and Simulation of Adaptive Nozzle Design in Material Extrusion

Abstract

This study proposes an adaptive nozzle design for material extrusion-based food additive manufacturing (AM), integrating both mathematical modeling and finite element analysis. A theoretical framework is developed to correlate extrusion radius and nozzle diameter with process parameters such as feeding speed, nozzle velocity, and shear rate. The proposed model is extended to estimate volumetric extrusion rate and incorporate rheological parameters using the Hagen-Poiseuille relation. To validate the derived equations, static structural simulations are conducted in a computer simulation under varying pressures, nozzle diameters, temperatures, and input feeding diameters. The simulation results show that increased pressure and higher temperatures enhance extrusion efficiency, while larger nozzles and feeding diameters reduce flow resistance and improve extrusion stability. Collectively, these findings validate the predictive capability of the mathematical model and highlight the feasibility of adaptive nozzle systems for optimizing extrusion performance in food AM. The study provides a preliminary foundation for the future development of dynamic nozzle control strategies that enable improved print fidelity and process flexibility.