Design of a Novel Integrated Solid–Liquid Separation and Mixing Pin Screw for CF-PLA Particle-Based 3D Printing: Fluid Simulation and Performance Evaluation

Particle-based 3D printing shows great potential in high-performance composite fabrication due to high raw material utilization and flexible material compatibility. However, constrained by conventional extrusion system structures, critical issues (non-uniform melt conveying, insufficient mixing efficacy, poor extrusion stability, etc.) remain. To address these, this study proposes a novel separate-type pin screw integrating solid–liquid separation (from split screws) and high-efficiency mixing (from pin screws) to improve CF/PLA composite extrusion efficiency and mixing homogeneity in particle-based 3D printing. Three-dimensional modeling, static strength/stiffness analysis, and POLYFLOW-based numerical simulation of particle melt conveying/mixing in the screw channel were conducted to analyze structural parameter effects on pressure field, shear rate, and mixing. Experiments assessed printer extrusion rate (different screws) and printed specimen mechanical properties. The simulation and experiment confirmed the optimized screw has better pressure distribution and mixing at 20 rpm, with optimal pin parameters: diameter 2 mm, height 1.6 mm, radial angle 60°, and axial spacing 10 mm. This work offers theoretical/structural support for particle-based 3D printing extrusion system optimization.