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Mostly 3d printable dual gear extruder

Yet another mostly 3d printable dual gear extruder

3D printer parts and enhancements

GPLv3

A free software license that requires that all work based on this must also be free software as in freely remixable and sharable by anyone under the same license but may be used commercially.

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Description

I wanted a little more torque (1:3 gearing) and also better filament grip. So I made a case that fits two gt2 pulleys and set of bondtech gears.

Materials and methods

Tension screw
(x1)extruder tension spring
(x1)m3 screw L50mm to tension latch
(x1) m3 brass incert L4mm for tension screw knob

Latch
(x1)m3 screw L30mm on latch hinge
(x2)m3 spacer L4mm ID3mm OD6mm on hinge

Top case
(x3) m3 screw L30mm to fascen top case to center case
(x1) m3 brass incert L4mm for tension screw
(x3) m3 spacer L4mm ID3mm OD6mm for filament insert and hinge
(x1) mr128 bearing L3.5 ID8mm OD12mm for 8mm extruder shaft
(x1) bowden coupler M9 thread 6mm tube insert

Center case
(x3) m3 brass incert L4mm to fascen top fasceners
(x1) mr128 bearing L3.5 ID8mm OD12mm for 8mm extruder shaft
(x3) m3 screw L28mm to fascen center case to bottom case

Bottom case
(x4) m3 brass incert L4mm for center fasceners
(x1) mr128 bearing L3.5 ID8mm OD12mm for 8mm extruder shaft
(x2) m3 screw L11mm to fascen top part of extruder
(x2) m3 screw L25mm to fascen bottom part of extruder

Additional parts
(x1) Shaft L55mmxD8mm (may have to add your own flat)
(x1) bondtech gear (3mm filament version) set with W4mmxL22mm rode
(x1) Gt2 60T pulley, belt width 10mm, center hold ID 8mm
(x1) Gt2 20T Pulley, belt width 10mm, center hole ID 5mm
Note: when tightening to motor shaft gear should protrude from shaft by .5 to 1mm
(x1) Gt2 closed loop belt L150mmxW10mm
(x4) m3 washers when fascening bolts to extruder motor

Shaft assembly (8mm)
bearing (from bottom case)
1mm spacer
pulley 60t (grub screw side "up")
.5mm spacer
bearing/center case
4mm spacer
bondtech gear
.5mm spacer
bearing/top case

Update Ultimaker firmware
download Tinkergnome:
https://github.com/TinkerGnome/Ultimaker2Marlin/releases
Upload using cura:
settings --> printer --> Manage printers --> Select printer and click update firware --> Upload custom Firmware

Change esteps on extruder
Maintenance --> Advanced --> preferences --> Motion settings --> Axis steps/mm
Change E from 282 to 587 (number derived from calibration test)
Save changes

Invert extruder direction
Maintenance --> Advanced --> preferences --> Motion settings --> Invert Axis
Invert E
Save changes

(optional) Run a 100mm calibration test
Create a file called "calibration.gcode" and add the following entries
M302
G91
G1 E100.0 F300
G90
Save it to an SD card and print it. It should move 100mm of filament through the extruder.

Notes:
Must use button head M3 screws
Use grease on bondtech gears
Use loctite on screws
Printed the case at 30mm/sec

Documents

Issues

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Comments

18e49862e00cd397002147d7aafb882d?default=blank&size=40Saul Mendoza printed this ago
Carousel thumb top case clip
Printed on:
Ultimaker - The Ultimaker 2
Result:
Updated top case (both) and latch to have the tension screw applying pressure closer to the filament. Also updated geometry on ultimaker bowden case and added cable holder.
Feedback:
Still a work in progress.
18e49862e00cd397002147d7aafb882d?default=blank&size=40Saul Mendoza commented ago

Added top case (Top case um bowden file) to accommodate the bowden clip used on the original extruder. Have not tested this part yet.

18e49862e00cd397002147d7aafb882d?default=blank&size=40Saul Mendoza printed this ago
Carousel thumb case fully assembled new
Printed on:
Ultimaker - The Ultimaker 2
Result:
Added new bottom and center case for a more tensioned gt2 belt. I felt like the previous case left the belt a little too loose for my liking. Also added a tension knob with some texture.
Feedback:
Took some time to get used to the new extruding power. I have to make sure the hotend can handle the flow, or else filament can build and flow out at an unexpected time and make the print look uneven. You have to make sure you have the hotend hot enough for the amount of volume your pushing through. Its different because before if my hotend was not hot enough then the extruder would just skip. Would like to hear from anyone else's experience :)
18e49862e00cd397002147d7aafb882d?default=blank&size=40Saul Mendoza published this design ago