Dyze Pulsar™ Pellet Extruder

Dyze is a company dedicated to the development and manufacture of components for 3D printers. Dyze produces hotends, sensors, nozzles and all kinds of accessories, although it specialises in the design of extrusion systems.

Among the extrusion systems developed by this manufacturer are its high-flow extruders, including Tiphoon and Pulsar™.

Pulsar™ is a high-flow pellet extruder aimed at large-scale 3D printing. The aim of this pellet extruder is to produce parts of 1 m³ or even more quickly. Pulsar™ is thus compatible with almost any large-scale 3D printer, but can also be installed on robotic arms.

Image 1: Pulsar™ pellet extruder. Source: Dyze Design.

High flow extruder

A high flow extrusion system refers to the amount of material that the extruder can process in a given period of time. In this case, Pulsar™ can process up to 500 mm³/s, or 2.5 kg of material in one hour.

To process this large amount of material in a short time, the Pulsar™ pellet extruder is equipped with an 1100 W heating system, which ensures a stable temperature at all times, even at high printing speeds.

Video 1: Pulsar™ high flow pellet extruder. Source: Dyze Design.

It goes without saying that a powerful motor is required for extrusion work. This extruder features a NEMA23 motor with high quality gears that allow it to handle a high material flow.

Thanks to these features, Pulsar™ is a high performance solution and one of the fastest pellet extruders on the market today.

Compatible with advanced materials

Pulsar™ is made of ultra-strong aluminium alloy and is designed for intensive work in all environmental conditions. To this end, it has the following features:

• Water cooling circuit: Ensures that the entire system maintains a constant temperature.
• Additional heat shield: Thanks to this, Pulsar™ can operate in environments up to 200°C.

In addition, heaters, temperature sensors and material extrusion components withstand temperatures of up to 500°C, and three high-precision PT100 sensors maintain a constant temperature, enabling the processing of advanced materials from the PAEK family, such as PEKK, PEEK, PEI Ultem or PSU.

Image 2: Spiral heaters for constant temperature. Source: Dyze Design.

Pulsar™ can also process technical and fibre-reinforced materials. Therefore, this pellet extruder is equipped with a highly abrasion-resistant tool steel nozzle. Thanks to this component, variations in nozzle diameter caused by fibre abrasion, which are common in long-term printing with these materials, are avoided.

This pellet extruder allows the nozzle to be changed, with output diameters ranging from 1 mm to 5 mm. The possibility of working with different materials and output diameters expands the manufacturing possibilities with this extruder, making it very useful for various applications in the industrial sector.

Image 3: Nozzles of 1 mm and 5 mm outlet diameter for Pulsar™. Source: Dyze Design.

High-performance system

The Pulsar™ pellet extruder has a uniform heating system thanks to the spiral heaters. In addition, the extruder screw design is fully customised, with three heating zones to ensure that the polymer is at a constant temperature.

1. The upper zone receives the pellets and melts them.
2. The central zone then stabilises the polymer to the required temperature in a precise manner.
3. Finally, the nozzle zone is maintained at a suitable temperature to ensure a uniform outflow.

Image 4: Customised extruder screw. Source: Dyze Design.

Pulsar™ is geared for industrial use, so Dyze has developed an optional automatic feeding system that detects the level of pellets, which can be supplied from a bulk source.

For all its features, high performance and the ability to process a wide variety of materials at high speed, the Pulsar™ pellet extruder is a great choice in large-scale manufacturing, allowing companies to produce prototypes or large final parts.