Compact direct drive extruder (Superfly remix) for Wanhao Duplicator 6 / Monoprice Maker Ultimate

thingiverse

I decided to remix the great superfly remix by NikNakTak to fit my Monoprice Maker Ultimate printer (Wanhao Duplicator 6 and Zortrax M200 are the same) This has factory extruder chassis clearances (unlike BMG), shortens extrude length, weighs significantly less, and is so easy to clean/load/work with comparatively. Saves about 20-30g off the extruder assy and another 20g or so not needing a mount anymore. All upsides. Housing: Adjusted to factory carriage bolt pattern with bolt ease of install clearances, notched the top of the nose to clear the chassis, and tightened up the outlet to fit a stub of PTFE. I also had to drop the thumbscrew just over 1mm to clear the chassis. Hopefully, yours clears too. Tensioner: edited to match the lower screw and I gave it a drop slot for a standard M3 nut. I also notched it to clear my 26mm gear that was rubbing. The notch is ugly but it works. I tightened the gear housing just slightly too. Bearing carrier: All of the options were too short. I made one that was slightly taller for tighter clearances. I recommend printing the other options on the original source and seeing what fits best for you since all clones are different. Breakout board mount: I remixed my favorite BMG mount from Inhaler to make a corner-mounted bracket. I left the tabs if you want a cable retainer, but, the flyweight option is just to zip tie your cable down (works great). This is the only part that needs supports and it's a little more of a pain but it works well. I'm using this with a pancake Nema 17 right now with great results @ 0.85A. I might try fitting a round NEMA 14 later (would shave another 50g or so doing it). Printed fine in Petg with no supports (except for board mount) at 0.16 layer height. Some of this is tighter than my source so you might need some post-processing but I wanted a more rigid lower clearance structure and didn't mind. This is, IMHO, the best extruder option for this chassis. All the parts can be salvaged from your old BMG extruder or "Dualdrive" clone (like mine). Make sure you have hardened machine cut gears if you want them to last (vs stainless M3 thread cut gears) Mounts with 3x M3x6 bolts and 2x m3x8 bolts. I only had m3x10 so I printed a few M3 washers from here https://www.thingiverse.com/thing:826065 to keep it from bottoming out. I also used a few for the spring base and closing up the space in the tensioner housing but probably not necessary.