This is a plastic extruder that's capable of extruding a lot of plastic. It's a work in progress.
here the entire Fusion360 file that has every component of this build.
Here's the current BOM
Not included in the BOM are custom parts that you'll need to fabricate by CNC milling and 3D printing parts.
The basic idea is to take plastic pellets and melt it down and extrude it through a custom shaped die. In order to do this, I used a 1" wood auger driven by a stepper motor to push material forward and heat bands to heat the material. There is also a thermistor to measure the temperature and a PID to close the loop and turn the heat bands on and off as needed. At the tip of the extruder is a mist cooling system that uses compressed air to draw water to the tip and sprays a mist onto the hot plastic so it cools down quickly. To control the flow of plastic, there's a potentiometer, finger trigger, and foot pedal to accommodate different extruding styles.
The current design of the hopper holds approximately 1.5lb of plastic pellets. This could easily be extended with a 1" tube to a larger hopper hosted elsewhere.
These parts make the bulk of the custom parts needed for the extruder. Two extra-wide shaft collars for 1.125" OD tubing to hold the different tubes in place.
The spider coupling housing is used to hold one end of the tube agains the stepper motor while housing the spider coupling (which provides just enough slop to prevent the auger from jamming)
Almost all the components in this build are held together with M6 screws (for easy disassembly and reassembly)