Direct drive extruder for Wilson or Prusa i3 rework

thingiverse

This is a direct drive extruder that I designed specifically for 1.75mm filament extrusion on my Reprap Wilson. To Use: It will connect to the standard X carriage (also compatible with the Prusa i3 Rework by eMotionTech) using four M4 x 20mm screws and nuts. A MK7 drive gear is used (a MK8 gear may also work, but only the MK7 has been tested). You will need three M3x30mm screws to attach the motor (one screw is also used to support the hinged lever). The Idler bearing is a 624RS bearing, held in place by a M4 x 20mm screw and locknut. Choose a spring that is one inch long when uncompressed, with decent tension of around ten pounds per inch. Through the spring, use a M3 x 50mm screw with a M3 nut going into the slot on the extruder. The hot end mount is JHead compatible and also works well with hot ends like the e3d v6. Two M3 x 30mm screws (possibly longer than thirty millimeters) are used to attach the clamp piece to the outer side of the hot end, secured by nuts. A fan mount is provided for a forty millimeter fan, requiring an additional M3 screw and nut for mounting and four more M3 screws with nuts to secure the fan in place. An included "key" allows manual turning of the extruder by pressing over the motor shaft so that it can be manually rotated, which only works with D-shaft motors. Assemble instructions are available in a video on YouTube: https://www.youtube.com/watch?v=z2bXSRLNdbQ Update, January 22nd 2015: The extruder body and idler were altered to add a slot for an additional tension spring, which helps prevent the idler from pushing flexible filament off course. Filament path has also been adjusted upward by several millimeters for better functionality.