Dual Extruder 3D Printer: Types, Principles and Tips

In the 3D printing industry, with the development of dual-extrusion technology, engineers can now use dual extruder 3d printers to print parts composed of two or more materials. Compared with traditional single-extrusion printers, dual extruder 3d  printers have significant advantages in functionality and application range, but at the same time, design difficulty and maintenance costs also increase. This article introduces the types, working principles, advantages and disadvantages, and printing techniques of dual extruder 3d printers to help users better understand and use this advanced equipment.

Types of Dual Extruder 3D Printers

The fixed dual-extrusion system is very similar to a traditional single-extrusion printer. By installing two nozzles on the same print head, the two nozzles work together, and the printer switches materials or colors by controlling the switch of the nozzles. This system has a simple structure and low cost, and is suitable for basic multi-color printing and simple multi-material requirements. However, since the two nozzles share the same motion trajectory, leakage defects may occur when switching materials.

The independent dual extrusion system (IDEX) uses two completely independent nozzles and motion trajectories. Each nozzle has its own independent motion system and can work independently in different areas, thereby avoiding material interference and cross-contamination. The IDEX system supports mirror mode and repeat printing, which is suitable for large-scale or high-efficiency production and usually has higher printing accuracy and quality. Excellent printers of this type on the market include Flashforge Creator Pro2, Snapmaker J1, etc.

Flashforge Creator Pro2

Source: https://www.amazon.co.uk/FLASHFORGE-Enclosed-Structure-Optimized-Platform

The hybrid extrusion system, integrates two materials into a single nozzle for simultaneous extrusion. This design allows for blending materials or colors directly during printing, enabling unique effects such as color gradients or mixed material properties. Its structure is more complex than fixed dual extrusion but remains less intricate than IDEX systems. It demands strict material compatibility and precise calibration to ensure smooth operation.

How dual extruder 3D printers work

The working principle of a dual-extrusion 3D printer is similar to that of a single-extrusion printer. The key lies in the coordination between the two nozzles. The printer analyzes the 3D model through slicing software, assigns different materials or colors to corresponding nozzles, and assigns printing paths to each layer. During the printing process, the nozzles are switched via a mechanical lifting or sliding mechanism to ensure that unused nozzles do not interfere with print quality. The two nozzles need to be precisely synchronized to ensure a seamless connection between different materials or colors, especially in complex designs where high precision is required.

Three types of extrusion for FDM printers

Source: https://www.researchgate.net/figure/a-common-FDM-printer-for-polymers-and-SFRC-b-Co-Extrusion-FDM-printer-for-CFRC-c_fig5_342855703

Advantages and Disadvantages of Dual Extruder 3D Printers

Advantages

1. Dissolvable support material

When printing complex models, one nozzle of the dual-extrusion printer is responsible for printing the main material, and the other nozzle is used to print the soluble support material, which can be easily dissolved and removed during post-processing without peeling or prying. In the final printed part No support marks will be left.

Source: https://www.bcn3d.com/technology

2. Strengthen filling

Strength and impact resistance can be improved through the combination of two materials (such as rigid and flexible materials or fiber reinforced materials), while supporting different density filling designs to optimize weight and structural performance.

3. Multi-color printing

Multi-color models can be printed directly without post-painting. Some slicers support dual-extrusion printers to achieve color gradient effects, which greatly facilitates the production of art and design models and is suitable for customized production.

4. Efficient production

The dual-extrusion printer using an independent nozzle system (IDEX) supports mirror mode and repeat printing mode, which can significantly improve production efficiency and save time.

Disadvantages

Dual-extrusion 3D printer equipment costs more and is more suitable for users with sufficient budgets. In addition, dual-extrusion printers are more difficult to maintain, requiring frequent cleaning and calibration of the nozzle when using different materials. For beginners, its operation and debugging are more complex and require more printing skills. At the same time, problems with material mixing or nozzle overflow may occur in the fixed dual-extrusion system, which affects the printing effect.

Printing tips

1. Calibrate the position of the nozzle: Ensure that the two nozzles are accurately aligned to avoid misalignment or material deviation, and ensure the accuracy and quality of each layer of printing.

2. Configure the slicer correctly: Enable the dual extruder function and set the extruder spacing accurately.

3. Adjust retraction settings: Optimize retraction parameters to reduce material drawing and contamination, especially when printing complex models, where details and accuracy are particularly important.

4. Clean the nozzle: Clean the nozzle regularly to avoid material clogging that affects the printing quality and ensure that the nozzle remains clear.

With its unique advantages of multi-material and multi-color printing, dual-extrusion 3D printers open up new possibilities for engineering design and customized production. If you are looking for professional online 3D printing services, JLC3DP will provide you with high-precision and efficient solutions to help your ideas become reality.