Bowden dual/quad extrusion extruder (single-nozzle single-drive) + video

thingiverse

It's been a while since I've uploaded anything new, but this project is really cool. You might know me from my Proximity sensor mount if you have a Prusa i3, which is pretty popular according to Thingiverse Analytics. I got interested in dual extrusion and started looking for solutions. At first, I found the well-known Extruder Merger, but then I discovered a Direct drive dual extruder that's single-nozzle and single-drive. This one is less bulky than using two stepper motors. Problem The direct drive dual extruder I found is not compatible with my bowden setup, so it won't work for me. Solution I converted the single-nozzle single-drive dual extruder to Bowden. It seems like a simple solution, but it took hours of recreating in Autodesk Fusion 360. Now you can combine this design with an Extruder Y-merger: Extruder Merger by mokash770 (PC4-01 Push fittings) Y-piece for dual extrusion with one nozzle by 3Dator (PC4-M5 Push fittings) If you want to switch between four filaments, you'll only need two stepper motors instead of the usual four. You can use a four-way Y-merger at the nozzle end. If someone makes this work, please share your G-code for switching. This design is similar to the Original Prusa i3 MK2 Multi Material upgrade release - dual/quad extrusion. The STL files have been exported with high quality and low Surface Deviation to achieve maximum print resolution. Printing Settings Printer Brand: RepRap Printer: Prusa Z3D Rework (Custom) Resolution: 0.1 Infill: 20 Notes: Use brim and also use Supports for the body. Print the washer up-side-down. For the left side, print a mirrored idler and washer in Cura 2.3.1 by clicking on the part and then mirror. I suggest using ABS to withstand the heat from the stepper motor. Other heat-resistant filaments will work fine too. If you have any issues with printing, check out this Troubleshooting Guide to 16 Common 3D Printing Problems by All3DP. My custom 3D printer is a Prusa Z3D Rework, and I designed this project in Autodesk Fusion 360. I kept most of the improvements from the previous design while making a few tiny changes. It's still untested, but you can make changes yourself or leave a comment if you have any questions. See the Fusion 360 playback on YouTube here: Fusion 360 - Bowden dual/quad extrusion extruder (single-nozzle single-drive) The first real-world test of this design went well, and now I'm waiting for the rest of the parts to arrive to test dual extrusion.