When you're looking to print faster or work with larger 3D printers, you'll eventually run into a discussion about filament size. Two options that often come up are the Dyze Pulsar™ system and traditional 2.85mm filament. While they might seem similar at first glance (after all, they're both bigger than standard 1.75mm filament), they work quite differently and each brings its own set of advantages to the table. Let's break down what makes each system unique and help you understand which might work better for your needs.
Understanding the Dyze Pulsar™ System
The Dyze Pulsar™ represents a relatively new approach to high-flow 3D printing. Instead of just making the filament bigger, the Pulsar system uses a unique pellet-fed design that's been scaled down to work with medium to large size 3D printers. Think of it as a mini version of the industrial pellet extruders you might see on giant machines, but engineered to work with more precise, smaller-scale printing.
Within the extruder is a screw inside a barrel, with heaters surrounding the barrel. Dry, solid pellets are poured into the feeding zone, which has plenty of room for the beginning of the heating process. As the pellets melt while progressing down the barrel, the diameter of the screw becomes larger which compresses the plastic. This pressure keeps the pellets flowing through the extruder. The melted plastic then travels from the compression zone into the extrusion zone, where it is forced through a nozzle and is ejected from the barrel.
The Dyze Pulsar™ can output up to 500 mm3/s or 3 kg/h of material, has 1100 watts of heating power, and weighs 7000 grams. For use in 3D printing, this all has to be attached to the gantry, which requires a very large system.
What Makes the Pulsar Special
The most obvious advantage of the Pulsar™ system is its ability to handle incredibly high flow rates. Because it’s feeding pellets directly into the melting zone, it can push through a lot more material than traditional filament-based systems. This means you can print much faster – we're talking about speeds that might make your regular printer look like it's moving in slow motion.
The system also gives you more flexibility with materials. Since it uses pellets, you can work with the same raw materials that injection molding machines use. This often means lower material costs (pellets are usually cheaper than filament) and access to a wider range of materials that might not be available in filament form.
Another interesting advantage is that the Pulsar system can change materials fairly quickly. Since you're working with pellets, you can simply pour in different material when you want to switch, rather than having to unload and load new filament spools.
The Challenges of Using Pulsar
However, the Pulsar system isn't without its complexities. For one thing, it requires more precise temperature control than traditional filament systems. The melting process needs to be just right, or you might end up with inconsistent extrusion or clogs.
Setup and maintenance can also be more involved. You need to make sure your pellet feed system is working properly, and cleaning the system thoroughly when changing materials is crucial to prevent contamination. There's also a learning curve in understanding how different pellet sizes and shapes affect print quality.
Drying the pellets is also an added challenge, as it is with any 3D printing methods, but this can be solved with a separate pellet dryer. These are usually placed outside of the 3D printer and contain a hopper for easy pouring. Many of these dryers also come with a auto refill system, shooting the dried pellets into the Pulsar.
The World of 2.85mm Filament
On the other hand, 2.85mm filament (sometimes called 3mm filament) represents a more traditional approach to high-flow printing. It's essentially a bigger version of the 1.75mm filament that most people are familiar with, and it's been around for quite a while in the 3D printing world.
Why People Choose 2.85mm
The biggest advantage of 2.85mm filament is its familiarity and simplicity. If you're used to working with 1.75mm filament, the transition to 2.85mm is pretty straightforward. The principles are the same – you're still feeding a continuous strand of plastic through a hot end, just with a larger diameter.
2.85mm filament can achieve higher flow rates than 1.75mm filament simply because there's more material to work with. This means faster print speeds, though not quite as fast as what you might achieve with the Pulsar system.
Many users also appreciate the stability of 2.85mm systems. Since the technology has been around longer, many of the kinks have been worked out, and there's a good understanding of how to optimize these systems for different materials and print conditions.
The Limitations of 2.85mm
However, 2.85mm filament does have its drawbacks. The larger diameter can make the filament less flexible, which can be an issue if your printer setup requires tight bends in the filament path. You might need to modify your printer's design to accommodate the stiffer filament and avoid breaks. Also, the stiffness of the filament can cause a large amount of friction if the filament path goes through a tube, making it difficult to push and pull filament through.
Storage can also be more challenging with 2.85mm filament. The spools are often bigger and heavier than their 1.75mm counterparts, and they're more susceptible to moisture absorption due to their larger surface area. This means you need to be extra careful about keeping your filament dry. Many large printers come with a heated filament storage cabinet, in which the temperature can be adjusted depending on the plastic material.
Another drawback is its fading popularity in desktop systems. While 2.85mm filament used to be standard in small scale 3D printing, it has been replaced by 1.75mm filament, which is better for more detailed but tiny parts. This makes 2.85mm filament slightly more difficult to find and purchase, but there is still a market for it, and it may never be phased out entirely.
Making the Choice
Your decision between these two systems will likely come down to what you're trying to accomplish. If you're looking for maximum print speed and material flexibility, and you're willing to deal with a bit more complexity, the Pulsar system might be your best bet. It's particularly good for situations where you need to print a lot of parts quickly or work with specialized materials.
If you're more interested in a proven solution that offers a good balance of flow rate and ease of use, 2.85mm filament might be the way to go. It's particularly well-suited for users who want to upgrade their print speed without completely changing their approach to 3D printing.
Looking Ahead
Both technologies continue to evolve. The Pulsar™ system is seeing ongoing development in terms of reliability and ease of use, while 2.85mm filament manufacturers are constantly developing new materials and improving their formulations. Whichever system you choose, you're likely to see improvements in capabilities and performance as the technology matures.
Remember, there's no one-size-fits-all solution in 3D printing. The best choice depends on your specific needs, experience level, and what you're trying to achieve with your prints. Take some time to consider your priorities and don't be afraid to ask other users about their experiences with both systems.
