Dyze Design, the renowned Canadian manufacturer of high-performance and high-throughput extrusion systems, such as the Pulsar® pellet extruder, Pulsar® Atom and Typhoon® 2.85 mm high flow extruder, is releasing its new high flow Zephyr™ extruder for 1.75 mm filament.
Harnessing Dyze Design’s MeltCore™ technology, it guarantees rapid melting and elevated flow rates of up to 685 grams per hour (154 mm³/s). This places it among the fastest printheads on the market for 1.75 mm filament.
“With such an exceptional flow rate, Zephyr™ is the perfect tool for achieving high-speed printing without compromising the quality of the printed parts,” said Simon Duchaine, Dyze’s Chief Commercial Officer. “It’s the ideal extruder not only for rapid prototyping but also, and most importantly, for small series production where time is a critical factor.”
Designed for Industrial Applications
Zephyr™ is the culmination of 10 years of experience developing industrial and large-format printheads for both robotics and Cartesian additive manufacturing.
“What’s interesting about the Zephyr is that it features all the best elements we’ve ever designed in our extrusion systems,” Duchaine said. “This solution offers a bridge between traditional desktop additive manufacturing and large scale industrial applications. We’ve been listening to our customers using additive manufacturing for a living and made sure we addressed their pain points and innovated as much as we could.”
Durable construction materials and precision engineering ensure that Zephyr™ can endure the demands of intensive use. The hardened alloy steel gears are built to last, offering consistent performance and reducing the need for frequent maintenance or replacement.
This durability translates to cost savings over the long term, as the extruder remains reliable even with heavy and intensive use. Moreover, all the internal components are easily accessible for maintenance and cleaning, meaning that maintenance tasks can be performed quickly and efficiently, reducing downtime.
Enhanced Filament Handling
The gear ratio stands at 3.1:1, ensuring a perfect balance between speed and torque. The robust gear system is designed to withstand continuous operation. Zephyr™ also incorporates a double grip mechanism guided by two idlers on a cam-locked slider mechanism. This design mitigates slippage and ensures better and faster feeding of the filament.
The extruder offers nine different tension settings to accommodate a broader spectrum of filaments, from very flexible to a bit oversized. This adaptability ensures that Zephyr™ can handle a wide range of materials, making it a versatile choice for diverse printing projects.
“The innovative filament tension adjustment feature ensures optimal extrusion for each material type, enhancing print consistency. Whether you are working with standard PLA or more challenging materials like soft TPU or TPE, Zephyr™ provides the adjustment needed for precise and reliable prints. This flexibility reduces the need for multiple extruders, simplifying the printing process,” Duchaine said.
Zephyr™ is equipped with two 70 W heaters and two PT100 temperature sensors, enabling the extruder to operate up to 500 °C, ideal for advanced and high-temperature materials like PEEK, PEKK, and PEI. These high-temperature capabilities open new possibilities for advanced applications, including in the aerospace, automotive, and medical industries.
The dual independent heaters ensure that each material type is extruded at its optimal temperature, enhancing the overall print quality. Faster heat-up times mean less waiting and more productivity, which is essential in fast-paced production environments.
Weighing less than 700 grams and with dimensions around 47 x 108 x 155 mm, Zephyr™ is compact and easy to integrate into various 3D printer setups. This versatility means it can be used in both smaller desktop printers and large industrial machines or robotic arms.
MeltCores™ are offered in nozzle sizes ranging from 0.4 mm up to 1.8 mm.
Preorder Now
Dyze Design is now officially accepting pre-orders for the Zephyr™ and plans to start order fulfillment later in July. To secure this cutting-edge high-flow extruder, visit https://dyzedesign.com/zephyr-high-flow-extruder/ or contact Dyze Design’s sales team at sales@dyzedesign.com.
About Dyze Design Inc.
Montréal-based company Dyze Design has been in the 3D printing industry since 2015, developing and manufacturing cutting-edge, high-performance, reliable, and innovative extrusion systems and 3D printer components for professional and industrial 3D printers. They are renowned for their Typhoon® high-flow extruder, Pulsar® and Pulsar® Atom pellet extruders, DyzeXtruder Pro extruder line, their Sentinel® and Orthus® filament detectors, and Tungsten Carbide Nozzles. Today, many 3D printer brands such as Roboze, Sharebot, Blackbelt, PodoPrinter, AON3D, Trideo, 3DPlatform, Filament Innovations, and robotic arm company Kuka have chosen their printheads, hot ends, extruders, or nozzles as OEM parts for their industrial or high-end 3D printers.