In the present work, a process based on the principle of polymer extrusion is developed: the extruder deposition process (EDP). This system uses a screw extruder to deposit the material on a computer-controlled positioning system to build components. Experiments (Box-Behnken technique is used for experimental design) are carried out to study the influence of three process variables: nozzle temperature, chamber temperature and road gap on bond strength (inter-road and interlayer) and surface finish. Surface roughness and ultimate tensile strength values are measured for test specimens. Analysis of variance (ANOVA) is used to determine the significance of process variables. It is concluded that the developed EDP eliminates many of the shortcomings of the systems developed based on the principles of extrusion and produces components having higher bond strength than that achieved in commercial fused deposition modelling (FDM) systems.