14/04/2026
How to Select Extruder Components for PA66 at 50%–70% High Filling Levels
When PA66 glass fiber content rises from 50% to 70%, the process shifts from melt-dominated mixing to a fiber-dominated structure where resin only acts as a wetting phase. At this stage, stability depends mainly on extruder screw elements, extruder shaft, and extruder barrel, rather than formulation.
Low-Shear Screw Element Design
High shear is no longer suitable in 70% glass fiber systems, as it causes fiber breakage and torque spikes. Extruder screw elements should use low-shear, high-distribution structures such as toothed mixing elements (ZME/SME) to achieve flow splitting and “penetration wetting” instead of aggressive dispersion.
Feeding Strategy
Resin must be fully melted before fiber addition, and glass fiber should be introduced in stages (e.g., 35% + 35%) to avoid overloading. This requires stable conveying and controlled throughput from the screw configuration.
Shaft and Barrel Requirements
Under low-speed, high-torque conditions, the extruder shaft must provide high rigidity and fatigue resistance to avoid deformation and misalignment. The extruder barrel must withstand severe abrasive wear, typically requiring bimetallic or Ni60 liners with hardness above HRC58.
Venting Design
High fiber content brings air and powder, so venting must use reverse screw elements for sealing and deep-channel designs for efficient gas release without disturbing flow stability.
Conclusion
Processing 70% glass fiber PA66 is a full equipment challenge. Only when low-shear screw elements, high-torque shafts, and high-wear barrels are properly matched can stable and continuous high-fiber extrusion be achieved.