This work presents a single-nozzle/bi-extrusion FDM technology featuring two material inputs and heating sections connected with a mixing device with a reinforced mixing mechanism. The device ensures uniform mixing of materials, consistent print quality, and functionality, while an air-cooling system allows printing with materials having different solidification temperatures. Trials with six Dryflex TPEs demonstrated precise regulation of material flows, enabling dynamic adjustment of material blends and creation of multiple functionalities in one product. The technology also creates functionally graded materials (FGMs) in transition zones, improving interlayer adhesion and mechanical performance. This advancement enhances production flexibility, efficiency, and product quality, and expands material availability for additive manufacturing.
Open access funding provided by RISE Research Institutes of Sweden. This work has been funded by BioInnovation, a Strategic Innovation Program and a joint efort by Vinnova, Formas and Energimyndigheten [grant number 2021–03711]