Da Vinci 1.0 Pro Replacement Extruder

thingiverse

23 January 2017 Update: Increased the diameter of the large hole on the Extruder Top (Version v1). This facilitates drive gear cleaning and debris removal. Reduce the PTFE connector hole diameter to 9mm to allow for better tap engagement. 22 November 2017 This is a complete replacement of the Bowden Extruder for the XYZprinting Da Vinci 1.0 Pro printer, with the exception of the Stepper Motor, which remains intact. Over time, the original extruder weakened, and the idler pulley loosened, becoming very noisy in operation. Materials like PTEG that require significant nozzle pressure to operate correctly began slipping between the idler pulley and the extruder gear, causing print failure or under-extrusion. The Da Vinci extruder assembly is overly complicated and contains circuitry to detect filament presence ahead of the gear/idler pulley and a feedback circuit to send filament movement back to the processor. Disabling both features has no apparent effect on normal printer operation but does prevent the printer from detecting filament installation/removal during Load/Unload operations, requiring manual signal entry through the front panel. Print Settings Printer: XYZprinting Da Vinci 1.0 Pro Rafts: No Supports: No Resolution: .25mm Infill: 30% Notes: The extruder idler is under constant pressure, making it essential to use stronger materials like ABS or PTEG rather than PLA. Post-Printing Gain Access to Extruder Assembly Remove and retain the following items: Both Side Covers Top Door Front Panel Top Aft Plastic Frame Remove Extruder and retain or discard at your option: Unload Filament, Disconnect PTFE Tube, Install Connector, Remove Gear set screw, Adjust gear position on Stepper Motor shaft. Extruder Filament Drive Gear Reassemble Printer Install Aft Printer plastic Top Frame Install Front Panel Cover Install Side Covers Install Top Door. Test Insert filament into the small aft hole in the lower Extruder Body until it touches the Gear. Select Load Filament on the printer front panel. The printer should grasp the filament and slowly pull it into the PTFE tube. Once the Hot End reaches the temperature set for loading filament, the Stepper Motor will advance the filament and extrude the normal amount. Confirm the filament has been loaded on the front panel. How I Designed This Modifications to an Existing Design This Bowden Extruder is based on a design by DWONH. The original design split the Extruder Body in half horizontally, allowing both halves to be printed without support. I changed the design to incorporate the filament channel and the Bowden Tube Connector hole in the bottom body, allowing for a more precise line bore of the filament path and a more secure attachment of the Bowden Tube Connector. The Extruder Body exterior was resized to fit onto the Da Vinci 1.0 Pro top aft frame with the covers installed. The input filament hole was enlarged to optionally allow insertion of a PTFE feed tube that routes the filament from the spool to the Extruder. The Lever Halves were reworked to more precisely fit the Idler Spring and Idler Bearing. Interior geometry was reworked in several places to give more room for the Idler and Lever. Custom Section Bill of Materials 3 M3x30 Screws 3 M3 Washers 1 M3 Hex Nut 1 M3x20 Screw 1 Compression Spring, Steel, Metric, 9.6 mm OD, 1.6 mm Wire Size, 12.6 mm Compressed Length, 21.5 mm Free Length, 211.82 N Load Capacity http://www.amazon.com/gp/product/B005S4F93Q 1 Double Sealed Precision Ball Bearing (688ZZ) 8 x16 x5 http://www.amazon.com/gp/product/B01FE2EVLW 1 MK7 Stainless Steel Teeth Extruder Gear With 5mm Bore & 40 Teeth http://www.amazon.com/gp/product/B016XTZ5AQ 1 PC4-M10 Male Straight Pneumatic PEFE Tube Push Fitting http://www.amazon.com/gp/product/B01IB81IHG