After twelve years of continuous development and feedback from research institutions worldwide, we’re proud to announce the most significant evolution in the Xcalibur lineage: the Noztek Xcalibur Servo.

This isn’t an incremental update. We’ve fundamentally re-engineered the drive system, control architecture, and thermal capability to meet the demands of advanced materials research — from high-performance PEEK composites to experimental polymer blends that push the boundaries of additive manufacturing.

The result? A desktop filament extruder that delivers industrial precision, research-grade data capture, and the thermal headroom to process materials previously reserved for production-scale equipment.

The Numbers That Matter

The most significant change is under the hood. We’ve replaced the proven but limited planetary DC motor with a 750W RS485 DC servo motor paired with a precision 20:1 planetary gearbox. This isn’t just more power — it’s a fundamentally different approach to extrusion control.

Closed-Loop Precision: The 17-bit incremental encoder provides real-time position and velocity feedback, enabling the controller to maintain ±0.1% speed regulation regardless of melt viscosity changes. When you’re processing PEEK at 380°C and the viscosity shifts as crystallisation begins, the servo compensates instantly.

Variable Speed Range: From 1 RPM for ultra-slow PEEK processing to 150 RPM for rapid PLA purging, you now have the full spectrum. The previous fixed-speed motor forced compromise; the servo eliminates it.

Torque Feedback: For the first time, you can monitor real-time torque and load data during extrusion. This transforms troubleshooting — you’ll see a blockage developing in the torque curve before the motor stalls, giving you time to intervene.

Built-In Brake: The servo includes a 24V electromagnetic brake that holds position when powered down. No more slow ooze from residual pressure — the screw stops exactly where you leave it.

600°C: Unlocking High-Performance Polymers

The upgraded heating system pushes operating temperature to 600°C, opening the door to materials that were previously impossible on desktop equipment.

Material Compatibility

The 600°C ceiling isn’t just about hitting a number — it’s about thermal headroom. When processing PEEK-CF at 400°C, you need margin for process optimisation without bumping against hardware limits. The Xcalibur Servo gives you that margin.

5-Litre Stainless Steel Hopper: Production-Ready Capacity

We’ve increased hopper capacity from 1.1 litres to 5 litres — a 350% increase. In practical terms, this means:
• Longer unattended runs (2+ hours at full throughput)
• Better suited for small-batch production, not just R&D
• Reduced operator intervention and handling of hygroscopic materials
• Full stainless steel construction for pharmaceutical and food-contact applications.

125% Throughput Increase: 2 kg/hour

The combination of higher motor speed capability and optimised thermal management increases filament output from 8 metres per minute to 10 metres per minute — approaching 2 kg per hour for standard thermoplastics.

This isn’t just about speed. For high-temperature materials like PEEK where processing time in the melt zone affects crystallinity and mechanical properties, the ability to run faster when conditions allow means better material outcomes — not just more output.

Command Center: Nexus Extrusion Control Hub

The Xcalibur Servo ships with our redesigned 7-inch touchscreen interface and the Nexus Extrusion Control Hub software — the same platform proven on the Noztek Nexus, now adapted for the Xcalibur’s extended capabilities.

Real-Time Telemetry

• Live temperature graphs for all three heater zones
• Motor RPM (both motor and gearbox output)
• Torque and load percentage — see blockages developing before they stall
• System messages and fault logging

Research-Grade Data Export

One-click CSV export captures every data point from your extrusion session. Feed it into your analysis pipeline, attach it to publications, or use it to build processing recipes for new materials. This is the traceability that research institutions and regulated industries require.

3-Step Workflow

Setup → Warmup → Run. The software guides operators through each stage with safety interlocks — the motor won’t run until warmup is complete, and emergency stop is always one button away.