Optimal Process Parameters for FDM‐Based 3D Printing of Metal‐Polymer Mixtures with Low‐Temperature Powder Feeding

Abstract

In this study, a proprietary powder‐fed 3D printer is employed to fabricate impellers from metal‐polymer mixtures via low‐temperature extrusion, simplifying the traditional complex metal molding process. By adjusting the extrusion speed and temperature, various quality impeller blanks are produced, identifying optimal printing conditions. The best results are achieved with a feed temperature of 170 °C, extrusion speed of 6 r min−1, printing platform temperature of 50 °C, and nozzle temperature of 175 °C, achieving a surface roughness of Ra = 9.973 μm. Post‐processing densification of the stainless steel wheels reach 97.23%, with a tensile strength of 255 MPa, elongation at break of 49%, and hardness of 60 HRB. These parameters meet the physical and mechanical standards required for general metal parts, demonstrating potential for precision metal processing in sectors such as aircraft engines, gas turbines, and high‐performance pumps.