Experimental Investigation of Heat Pipe-Assisted Cooling for Heat Creep Mitigation in FFF Extruders

Heat creep is a critical failure mechanism in fused filament fabrication (FFF) extrusion systems, arising from insufficient thermal isolation between the hot end and cold end. It causes premature polymer softening, extrusion instability, and nozzle clogging, especially when active cooling is reduced or lost. This study experimentally evaluates passive cooling strategies for mitigating heat creep in consumer-class printers by exploiting ambient thermal stratification within the build volume. Vertical air-temperature gradients above heated build plates were measured for enclosed, semi-enclosed, and open-frame architectures, revealing pronounced stratification. Cold-end temperatures were then quantified for a stock extruder under forced and natural convection while printing polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS). Finally, a modified cold-end using a heat pipe to relocate heat rejection to an elevated heat sink was tested under identical conditions, assuming fan failure. Elevated heat-rejection locations experienced lower ambient temperatures and improved natural-convection heat transfer. Relative to the stock configuration, the augmented design reduced cold-end temperatures and improved thermal stability during representative printing cycles without continuous active cooling—the improvement percent is ~8%. The results demonstrate that coupling heat-pipe conduction with environmental thermal gradients can mitigate heat creep and improve extruder reliability with lower energy demand.