PULSAR S2 Engine airflow issue - affects units shipped before Dec 22, 2025
This article aims to explain the technical challenges we faced right after starting mass production of the PTX, what lessons we learned, how we resolved them, and what impact this has on shipping timelines.
What’s the Issue?
In some units, the engine does not cock after pressure is connected, resulting in free airflow through the barrel. We have identified both the root cause and why our tests did not detect this defect.
Root Cause
An excessively thick anodized layer on the rear part of the engine causes the nozzle to move inside the cylinder with too much friction. As a result, the engine does not cock after pressure is applied.
This does not affect all units — only those with an unusually thick anodized layer. However, due to the nature of the defect, we are treating this matter with maximum caution.
Initially, we assumed the issue was caused by nozzles being 50 µm shorter than designed, which we intended to fix by replacing the O-ring with a thicker one. This solution was implemented in engines already sent out for replacement and in subsequent production units (approx. 10+ units).
The issues described above may only affect units shipped before December 22, 2025. If you have encountered any issues, please contact our support team.
Our Solution
- We have halted all shipments to eliminate the risk of sending any further affected units.
- On December 29, after the holiday break, we resumed work and immediately started producing new nozzles with dimensions perfectly matched to the anodized layer thickness.
- We are completely changing our testing system to ensure this issue cannot recur in the future.
Why didn’t the tests detect this?
Our previous testing method was flawed. It started with high-pressure checks to verify engine sealing. If the engine didn’t cock, employees would block the barrel to force the nozzle into position. After this, subsequent tests were passed, and the engine was approved for shipment.
However, recent checks revealed that engines passing these tests failed at low pressure (80 PSI), directing air through the barrel instead of cocking. This proved the engines were non-functional and the procedure inadequate.
What’s Changed?
We have completely revised the testing process. Engines are now tested first at low pressure, and only after passing this step do they proceed to high-pressure testing.
Update #1 (29-12-2025)
ℹ️We’ve implemented extensive modifications to the PULSAR S2 engine to fully eliminate the issue. The nozzle and needle have been redesigned, and a new spring introduced. Engines must now pass tests under extreme conditions: –10°C temperature and 3 bar (43.5 PSI) pressure.
Every affected customer will receive a new engine equipped with the updated nozzle, needle, and spring, fully tested under these conditions.
Update #2 (30-12-2025)
ℹ️ Extended testing of a larger batch of improved S2 engines has been successfully completed. The problem has been fixed.
What Lesson Did We Learn?
This experience showed us that a complex process means even minimal deviations in tolerances — whether in machining or anodizing — can have significant consequences. That’s why we’ve drawn the following conclusions:
- 100% of pistols will be inspected before shipping.
- Multi-stage quality control will be implemented throughout production.
- We will consider external factors such as sub-zero temperatures and the effect of time on engine performance.
- Every engine will be tested by two independent people before approval.
- We have changed our testing procedure to include pressure levels lower than the declared operating range, ensuring the pistol works reliably even under varying temperature and pressure conditions.
What’s next?
Every customer who reports this problem will receive a brand-new, complete engine at our expense.
Thank you for your trust, understanding, and for helping us improve our products — your feedback directly contributes to making them better and more reliable.