Frequent jamming at the screw feed area with virgin PETG on Pulsar extruder

[Yaxin]

Hi,

We’ve been using the Dyze Design Pulsar system for about two years now, and recently we’ve been experiencing a recurring issue: the filament (virgin PETG) keeps getting jammed right at the screw feed area — specifically where the material gets caught in the gap between the screw and the barrel.

We’ve checked both the screw and the barrel, and while there is some visible wear, it doesn’t look particularly severe. Still, the jamming happens frequently now, even with clean, dry virgin PETG.

Please see the attached image for reference — it shows the area where the material tends to get stuck.

Is there any known cause or recommended solution for this issue?
Could this be related to screw wear tolerance, barrel surface finish, or possibly material buildup or slight misalignment?

Any advice or troubleshooting tips would be greatly appreciated.

Thanks,
Yaxin

[Technical Support]

Hi Yaxin,

Thank you for reaching out with your troubleshooting question. We have indeed observed this type of behavior with some of our clients, particularly when processing PETG using cylindrical pellets. This is often accompanied by a high-pitched "squeaking" noise as the material creates friction between the inlet and the screw.

Switching to rounded pellets (typically produced via underwater pelletizing rather than strand pelletizing) can often resolve this issue by allowing the material to feed more smoothly.

Additionally, please check the motor connector for any signs of heating or corrosion, as a compromised connection can lead to a reduction in motor torque, contributing to the jamming.

Finally, could you please provide us with the serial number of your Pulsar extruder? This will help us check your unit's specific configuration.

Regards,

Andy (Andréanne Poulin - She / Her ) Support Team - Tier 1
	100-1505 Estelle-Mouton Lemoyne, Quebec, Canada, J4P 3S2
	dyzedesign.com

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[Rino Côté]

Bonjour Andréanne.

SVP, m’enlever de la suite de courriels. Je ne sais pas ce que je fait là… 

Merci 

 

Rino Côté

Le 18 nov. 2025 à 10:03, Technical Support <sup...@dyzedesign.com> a écrit :

Hi Yaxin,

Thank you for reaching out with your troubleshooting question. We have indeed observed this type of behavior with some of our clients, particularly when processing PETG using cylindrical pellets. This is often accompanied by a high-pitched "squeaking" noise as the material creates friction between the inlet and the screw.

Switching to rounded pellets (typically produced via underwater pelletizing rather than strand pelletizing) can often resolve this issue by allowing the material to feed more smoothly.

Additionally, please check the motor connector for any signs of heating or corrosion, as a compromised connection can lead to a reduction in motor torque, contributing to the jamming.

Finally, could you please provide us with the serial number of your Pulsar extruder? This will help us check your unit's specific configuration.

Regards,

Andy  (Andréanne Poulin - She / Her ) Support Team - Tier 1
	100-1505 Estelle-Mouton Lemoyne, Quebec, Canada, J4P 3S2
	dyzedesign.com

On Thu, Nov 13, 2025 at 12:58 AM Yaxin <deli...@gmail.com> wrote:

Hi,

We’ve been using the Dyze Design Pulsar system for about two years now, and recently we’ve been experiencing a recurring issue: the filament (virgin PETG) keeps getting jammed right at the screw feed area — specifically where the material gets caught in the gap between the screw and the barrel.

We’ve checked both the screw and the barrel, and while there is some visible wear, it doesn’t look particularly severe. Still, the jamming happens frequently now, even with clean, dry virgin PETG.

Please see the attached image for reference — it shows the area where the material tends to get stuck.

Is there any known cause or recommended solution for this issue?
Could this be related to screw wear tolerance, barrel surface finish, or possibly material buildup or slight misalignment?

Any advice or troubleshooting tips would be greatly appreciated.<????_2025111313 5418_261_58.png>

Thanks,
Yaxin

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