Polymer rheology profoundly influences the intricate dynamics of material extrusion in fused filament fabrication (FFF). This numerical study, which uses the Giesekus model fed with a full rheometric experimental dataset, meticulously examines the molten flow patterns inside the printing nozzle in FFF. Our findings reveal new insight into the interplay between elastic stresses and complex flow patterns, highlighting their substantial role in forming upstream vortices. The parametric map α–λ from the Giesekus model allowed us to sort the materials and connect the polymer rheology with the FFF nozzle flow dynamics. The identification of elastic instabilities, the characterization of flow types, and the correlation between fluid rheology and pressure drop variations mark significant advancements in understanding FFF processes. These insights pave the way for tailored nozzle designs, promising enhanced efficiency and reliability in FFF-based additive manufacturing.
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