Bondtech Prusa 2.5 V6 to Bondtech 2.5S Mosquito

thingiverse

I'm upgrading my Prusa i3 mk 2.5 v6 with a Bondtech hotend upgrade and decided to swap it out for a Mosquito hotend instead. The issue is that Bondtech doesn't sell the plastic parts separately, so I only need the metal or electronic components. The good news is that Bondtech has made their .STEP and .STL files available on GitHub, but they haven't pulled everything from the .STEP files yet. Luckily, I've done some digging for you and extracted the necessary parts from the .STEP files along with those from Prusa. You can find all the necessary parts at https://www.prusa3d.com/prusa-i3-printable-parts/. To make things easier for you, I've included a link to the required parts pulled from the .STEP files at https://github.com/BondtechAB/Bondtech_Prusa_i3/tree/master/CAD-Files. The Bondtech Prusa Housings come with threaded inserts due to their printing method (Selective Laser Sintering / Powder Bed Fusion), but FDM isn't limited by this. Since I didn't want to order and wait for threaded inserts, I've included GCODE files that utilize a pause feature to allow an M3 square nut in place of the threaded inserts. The print pauses four times for the Front housing: 1. After printing layer 1 (1* 0.20mm = 0.20mm) due to the fan mount feature (hexagon). It's essential that this feature sticks to the bed, or it's not worth continuing the print. 2. After completing layer 9 (9* 0.20mm = 1.8mm) to ensure an important mounting feature forms correctly. The print should be aborted and retried if this feature didn't form properly. 3. After completing layer 23 (23* 0.20mm = 4.60mm) to add the square nut to the Pinda probe. 4. After completing layer 24 (24* 0.20mm = 4.80mm) to add the square nut where the blower fan holder will mount. The print pauses three times for the rear housing: 1. After completing layer 23 (23* 0.20mm = 4.60mm) to allow a square nut to be added. 2. After completing layer 48 (48* 0.20mm = 9.60mm) to allow a square nut to be added. 3. After completing layer 116 (116* 0.20mm = 23.20mm) to allow a square nut to be added. You can find more details in the pause/resume screenshots. The file includes some supports, not a full auto-generated set of supports. The GCODE file is set for PET at 250C hotend and 95C print bed temperature with a 0.2mm layer height and 20% fill GRID infill pattern. My prints are in progress; I'll post pictures with successful assembly once they're complete.