Building a Glass 3D Printer: Design and Fabrication of a High-Temperature Hotend

Abstract

This thesis explores the design, fabrication, and optimization of a hotend system for 3D printing with borosilicate glass. The study addresses key challenges such as achieving precise temperature control and stable material extrusion at high temperatures. The hotend was constructed using VITCAST 1700STD, a dense refractory castable material selected for its superior thermal resistance and durability. An alumina tube integrated with a Kanthal wire heating element ensures efficient heat transfer and consistent filament flow, while stainless steel bolts and nuts provide stable electrical connections. Simulations conducted in COMSOL Multiphysics were essential for optimizing heat distribution, structural integrity, and material behavior under thermal stress. Low temperature experiments were conducted that seem to confirm the results from simulations at lower temperature.