Model droplet formation in extensional filament stretching within a Filament Extension Atomizer

Abstract Further innovation in the field of selective laser sintering (SLS) is strongly connected to the availability of new materials since the market is dominated by polyamide 12 (>90%). The aim of this publication is to develop a descriptive model for the droplet formation process in a Filament Extension Atomizer to predict the applicability to exploit further polymers for the SLS process. The feasibility was tested, investigated and characterized using a “Dripping out of a nozzle” setup for uniaxial extension. The droplet formation process was then observed via high-speed camera imaging and classified for certain parameters. The experiments were carried out using semi-diluted polyethylene oxide (600–4000 kg/mol), glycerol and water solutions as model fluids. Driven by the Plateau-Rayleigh instability, different types of spherical droplets were observed and various droplet formation mechanisms demonstrated and analyzed. Based on the experimental results, a predictive model is derived to describe various essential parameters.