Direct drive extruder for hypercube printers

thingiverse

Inspired by Hypercube Evolution extruder, combined with the power of direct drive extruder and, BL touch and a filament sensor extruder. To be able to print flxible filaments I needed direct drive extruder, plus i wanted to change my nozzles often. On standard prusha i3 MK3S extruder the process of changing nozzle is a real proccess. I wanted an extruder that makes it as easy as possible. ## Features - Easily maintainable - Direct drive - Supports BL touch - Filament sensor - Supports E3D Volcano type hotend - Extruder is exchangable, locking mechanism is compatible with Hypercube Evolution X-Carrige - Supports Hypercube Evolution Optical sensor homing, but I used it with sensorless homing ## Parts ### Electronics and movement - **Optical Sensor**: https://www.banggood.com/TWO-TREES-10pcs-Optical-Endstop-Light-Control-Limit-Optical-Switch-for-3D-Printer-p-1510313.html - **Prusha extruder gears**: https://www.banggood.com/1Set-Prusa-i3-MK2-or-MK3-Cloned-Btech-Dual-Gears-DIY-Steel-Pulley-Kit-For-3D-Printer-Gears-Extrusion-Wheel-Part--p-1382515.html - **Prusha idler spring** (any 15mm length, 3mm diameter, sufficiently tight spring will do): https://shop.prusa3d.com/en/spare-parts/599-idler-spring.html - **Turbine Fan 24V**: https://www.banggood.com/DC24V-Cooling-Fan-Ultra-Quiet-Turbine-Small-DC-Blower-5015-For-3D-Printer-Circuit-Board-p-1108987.html - **Nema 17 lenght 23mm**: https://www.banggood.com/HANPOSE-17HS4223-23mm-Nema-17-Stepper-Motor-42-Motor-42BYGH-0_7A-14N_cm-4-lead-for-3D-Printer-Extruder-J-head-Bowden-Titan-Extruder-p-1437267.html - **BL Touch** (I used knockoff for proof of concept): https://www.banggood.com/Geeetech-TL-touch-Auto-Bed-Leveling-Sensor-With-High-Compatibility-For-3D-Printer-p-1154826.html - **E3D Volcano Hotend** (I used knock off as a stand in but I designed for volcano), 1.75mm filament, 24V Direct Drive: https://e3d-online.com/products/volcano-hotend ### Threaded bras inserts I used cheap ones from banggood, but like after they pulled out the 2nd time when I was fastening the hotend, I realized, my time is more valuable than what I saved ;D - Ruthex RX-M3x5.7 threaded inserts: https://www.amazon.co.uk/ruthex%C2%AE-threaded-RX-M3x5-Press-fit-ultrasound/dp/B07YSRGZ9N ### Screws - 1x M3 lenght 40mm - 2x M3 lenght 30mm - 1x M3 lenght 25mm - 1x M3 lenght 15mm - 2x M3 lenght 12mm - 2x M3 lenght 10mm - 4x M3 lenght 8mm - 2x M3 lenght 6mm Box of screws I used: https://www.banggood.com/Suleve-M3SS2-M3-442Pcs-Stainless-Steel-Allen-Bolt-Nut-Hex-Socket-Cap-Screw-Assortment-Kit-p-1076216.html ## Known issues - fan and duct do not provide enough cooling for printing with 0.8mm layer height - optical sensor works unreliably with certain fillaments (especialy reflective PETG) ## Optional: Cable connectors I got MicroFit 3.0 connectors from my local electronics store. You will have to find a supplier near your location. For the hotend connection I used 12A locking connctor, but i cannot find an international supplier for these - 3x **Molex MicroFit 3.0 Plug 1x2**: https://www.molex.com/molex/products/part-detail/crimp_housings/0436400201 - 3x **Molex MicroFit 3.0 Receptacle 1x2**: https://www.molex.com/molex/products/part-detail/crimp_housings/0436450200 - 1x **Molex MicroFit 3.0 Plug 1x3**: https://www.molex.com/molex/products/part-detail/crimp_housings/0436400311 - 1x **Molex MicroFit 3.0 Receptacle 1x3**: https://www.molex.com/molex/products/part-detail/crimp_housings/0436450300 - 1x **Molex MicroFit 3.0 Plug 2x2**: https://www.molex.com/molex/products/part-detail/crimp_housings/0430200400 - 1x **Molex MicroFit 3.0 Receptacle 2x2**: https://www.molex.com/molex/products/part-detail/crimp_housings/0430250400 ## Terminals **Female** terminals go into **plug** housing **Male** terminals go into **Receptacle** housing - 50x **Micro-Fit 3.0 Crimp Terminal, Female**: https://www.molex.com/molex/products/part-detail/crimp_terminals/0430300002 - 50x **Micro-Fit 3.0 Crimp Terminal, Male** https://www.molex.com/molex/products/part-detail/crimp_terminals/0430310002