As the 3D printer market continues to grow, machines are becoming more reliable and faster, and key components that determine the functionality of the printer, such as extruders, hot ends and nozzles, are gaining more and more importance.
July 6, 2022 - Canadian company Dyze Design tries to offer a set of solutions for a wide range of machines and has developed high-performance extruders such as the Pulsar or Typhoon. These extruder services range from standard fused deposition manufacturing (FDF) tabletop machines to specialized pellet extruder solutions. By offering high-speed print heads with leak-proof systems, DyzeDesign wants to ensure fast, accurate, and repeatable FDM printing processes.
3D printer manufacturer DyzeDesign
Dyze Design is a Montreal-based company engaged in developing, manufacturing and marketing 3D printer components, mainly heating heads, extruders, sensors and other types of accessories that control the supply and storage of raw materials. The company's mission is to enable people to create the tools and things they need, whenever and wherever they need them. This mission is achieved by developing products that improve the reliability and usability of 3D printers by printing new materials.
In short, we want to be the Intel Inside of 3D printers, positioning ourselves as the leading supplier of extrusion systems for all printers operating on the Material Extrusion (MEX) principle, especially at very high industrial throughput," said Xavier Geremia, Dyze Design's sales representative and account manager. i.e. for industrial and robotic technologies.
Currently, the desktop 3D printing market is still dominated by filament systems, although the use of pellets is very common in the plastics industry, especially in injection molding. the RepRap movement further popularized the use of FDM printers and began to start using filament materials in large quantities in both the consumer and industrial markets. In short, the use of plastic pellet-based raw materials is relatively new to 3D printing, but the advantages are significant, especially for large-format printing and high extrusion rates.
The advantages of pellet 3D printers
Of course, granular 3D printing has its several advantages. First, for the same amount of material, the cost is on average 3 to 4 times lower than filament, and Pulsar targets ultra-large industrial high-speed printers that can extrude up to 2.5 kg of material per hour, resulting in significant cost savings. What's more, filament spools of more than 1 kg are quite rare. High-consumption systems for fine filaments, such as Dyze's Typhoon, require regular spool changes.
Secondly, pellets are a more ecological and flexible solution in the eyes of many industrialists and manufacturers. They can produce their own pellets, especially using recycled materials (so-called "repro"). Finally, pelletizing offers a lot of flexibility in terms of material selection: some polymers do not exist in filament form at all, because their properties do not allow them to be processed, but they can still be extruded to form parts.
The considerations when using pellet feed for printing are similar to those for using filaments, but are more sensitive to moisture. Therefore, it is important to use desiccants to store certain types of materials in moisture-proof containers; moisture is the number one contributor to print distortion. In addition, the use of a pellet delivery system to avoid manual filling of the material pattern is an equally important point to keep in mind.
The advantages of Dyze Design high-speed extruders
In recent years, there has been a trend towards "speeding up" printers (e.g., printers with speeds of about 300 mm/s). This is a good trend, but in reality, it is not useful to increase the printing speed if the extrusion system is not capable of extruding at high speed. In short, even at medium printer speeds, a high-speed extrusion system will greatly reduce print times, because such a system means more material per second. This is especially true because larger nozzles are typically used and the diameter of the lines and layers will be much larger. This is ideal for printing large parts on the increasingly popular large printers (BigRep, Modix, 3DPlatform, etc.).
Obviously, high throughput means a lot of molten material. In high speed printing, especially large format printing, parts tend to warp more because each layer doesn't have time to cool down fast enough. Therefore, it is important to use a good active cooling system, but also to have "additive manufacturing design" logic to ensure that the layers are well supported by each other.
A common disadvantage of high-speed particle systems is that they can only print in "vase mode". Since shrinkage is almost impossible using the screw extrusion principle, the material will continue to flow (bleed/leak) as it moves. In our case, however, our Pulsar uses a leak-proof system in the nozzle that allows movement in the X and Y directions for multi-part printing, or rather is not limited to vase mode.
The Dyze Design extruder's distinctive hot-end part
Today, specialized manufacturers engaged in 3D extrusion are offering a growing number of products that are highly reliable and adaptable to user limitations. This is actually very good news, as it shows the growing interest in additive manufacturing and the ability of extrusion system manufacturers to adapt to all the new challenges and constraints of a booming market. says Geremia: "With this logic, our products are positioned at the very top end of the range, perfectly meeting the needs of users, especially industrialists with more advanced manufacturing and engineering constraints of industrialists. Our extruders are made of 100% metal, can withstand severe shocks or vibrations, and allow for extrusion temperatures of 500°C for printing any polymer on the market. In addition, our systems can withstand high temperature environments up to approximately 80°C and are reliable and durable. Our philosophy is also to provide products that are adapted to the open source environment, allowing each user to use their own ecosystem to meet their needs and challenges. "
Almost all the components of Dyze Design's high-speed industrial extruders Typhoon and Pulsar are designed and machined directly by the in-house production team at the Montreal plant, allowing them to offer the best quality while being sensitive to every constraint.