When engaging in polymer printing, the structure and quality of 3D printed samples are contingent upon numerous adjustable parameters. The focus of this article is to examine the disparities in the capabilities of 3D printer head nozzles employing fused deposition modeling (FDM) technology, while also considering the influence of software/technical methods that regulate filament extrusion. The study in question delves into the intricacies of how the structure/material of said nozzles (including composite variations) impact their performance, ability to print abrasive materials, and danger of clogging. The primary objective of this research endeavor is to attain the thinnest possible thickness of the printed fiber for each respective material (filament). Additionally, the shape of cross-section, uniformity of the fiber, adhesion to the print bed, and instances of breakage are taken into account. It is worth noting that the refinement of the fiber structure frequently correlates with the temperature range during filament extrusion, thereby affecting its flowability, which, in turn, generates an inverse relationship with the diameter of the nozzle. It has also been substantiated that there are techniques that effectively assist in achieving finer structures that are unobtainable through standard printing methods. Furthermore, it is crucial to acknowledge the sensitive fact that many of the polymers tested encounter difficulties in producing fibers measuring 0.2mm, let alone 0.05-0.1mm.
The conducted experiments have demonstrated that, when approaching the limitations of printing, the elongation capability of materials without fracturing assumes a critical characteristic. Composites encompassing various fillers, whereby the size of grains can also present an obstacle when printing with nozzles featuring the smallest possible hole diameters, were also scrutinized.

The acquired results are classified to facilitate a comprehensive comprehension of the relationships between nozzle types, material variations, and printing parameters, while also indicating their best potential in terms of fine detail and quality. In essence, the findings have reassured that the adjustment and balance of the entire system in attaining the established objectives wield a significantly greater influence than individual components.



This project has received funding from the Research Council of Lithuania (LMTLT), agreement No: P-PD-22-049.