An Improved Flexible Filliment Extruder

thingiverse

This is an experimental Flexible Filliment extruder using the mechanicals from a Bondtech extruder combined with a zero backlash belt design and a Wade-style motor mount, coupled with the feed tube of a Lulzbot flexystruder. It's expected to extrude flexible filliment faster, with greater retraction accuracy, and less weight than alternatives. Print Settings Printer Brand: LulzBot Resolution: 0.5mm Infill: 80% or better Notes: You will only need support for the fan duct return. Everything else prints without it. Hardware required: 1 High-torque 65T plastic GT2 pulley with an 8mm bore, flanges, and a set-screw. 1 High-strength 36T aluminum GT2 pulley with a 5mm bore, flanges, and a set-screw. 1 Strong, high-quality GT2 belt with a 200T pitch, 6mm width, fiberglass-reinforced, and closed-loop (Gates GT2 2mr-88-5 or 2mr-88-3). 1 Long M8 bolt with a length of 68mm. 2 M8 washers for added protection. 2 Durable 608 bearings for smooth motion. 2x High-strength cap screws, 4.5mm in diameter, and 55mm long. 2x M4 nuts for extruder mount reinforcement. 2x Strong M4 washers for extra stability. 4x Short-high strength M3 10mm SHCS screws for stepper mount. 2x Medium length high-strength M3 10mm SHCS screws for Side pod mount 1 Long M3 SHCS, 14mm in length. 1 Low-profile tensioner screw, 8mm long. Bondtech's reliable mechanical kit (http://shop.bondtech.se/ec/kits/bondtech-extruder-v2-30-mechanical-kit.html), designed specifically for the Bondtech extruder series. M3 cap screws and thumbscrews with a 12mm length 75mm PTFE tube, 0.25"OD x 0.125"ID (6.5mm diameter) Durable drillbits from Mcmaster Carr: A powerful 6.5mm drillbit for enlarging filliment tube areas. Strong and precise 3.2mm drillbit for widening the PTFE tube. Long-lasting, robust 13mm drillbit for precision cutting. Installation of components starts with printing the main body pieces along with all required subcomponents. Insert two high-strength M3 inserts in the extruder's side pod assembly and one on the tensioner mechanism for better rigidity and durability. Afterward press-fit secondary wheel shaft on both sides into their respective places. Take main housing part of machine and enlarge 2 holes in center area to enable insertional attachment of tube by employing drill bit of appropriate size. Now carefully place PTFE rod from inside hole made previously into new, larger central area made before inserting second rod. Final assembly involves placing a large high-quality GT2 belt pulley at the opposite end, which will be tightly screwed onto retaining screw after fitting into the extruder housing part as well. Install standard hexagon hotend following regular steps mentioned in documentation and bolt down securely according to necessary requirements. Additionally you may have access by way of easy accessibility from above; that would result in smooth mounting without issues. For installation proceed in this manner: First insert both small high strength steel bearing on both side so that main part does not fall while placing them in machine. Press-fit hobbed wheel directly into place, along with its respective assembly components to ensure complete safety. Place larger pulley on opposite end following same instructions given earlier. At last simply fasten and install motor mounting component using proper securing screws ensuring there's good enough friction applied without applying too much tension on mechanism during use because of that specific adjustment is done accordingly.