L2M Next-Gen Pellet Extrusion 3D printer: Eliminating Barriers to Performance and Precision

This project focuses on solving key problems in large-scale pellet-fed 3D printing, a technology that holds great promise for cost-effective, sustainable manufacturing. Unlike traditional 3D printers that use expensive filaments, pellet-fed printers use raw plastic pellets directly, making them more affordable and flexible for industries like construction, automotive, and tooling. However, the current systems have three big issues which are weak bonding between printed layers, material stringing or oozing during pauses, and poor blending of recycled or composite materials. These problems lead to print defects, extra waste, and unreliable performance, making it harder for companies to adopt this technology for real-world use.
To address these issues, the intern will help refine and validate a new hardware system that includes a square-profile nozzle (for stronger bonding), a mechanical anti-oozing valve (for cleaner prints), and a built-in polymer mixer (for blending different materials in real time). The intern will also study the Canadian market, assess the system’s performance under local manufacturing conditions, and build a commercialization strategy based on stakeholder interviews, standards research, and business modeling.
As a partner organization, will benefit by being closely involved in the early-stage development of a scalable, Canadian-made 3D printing innovation. This aligns with the mission of supporting high-growth startups and manufacturing solutions. The project will generate a validated prototype and commercial insights, making it easier for partner organization and its network to evaluate and support the launch of the technology. Additionally, this collaboration will help position it as a key enabler in bringing advanced, sustainable manufacturing technologies to market, expanding opportunities for job creation, clean tech leadership, and business growth in Canada.

Faculty Supervisor:

Mohammad Abu Hasan Khondoker

Student:

Partner:

North Forge

Discipline:

Engineering

Sector:

Education; Management of companies and enterprises; Professional, scientific and technical services

University:

University of Regina

Program: