E3D Titan extruder for i3 - Modified

thingiverse

Gyrobot's X-carriage design had come close to meeting my requirements, but it still needed a few tweaks to be perfect for my needs. So, I decided to make some changes. To start with, I replaced the four linear bearing setup with three bearings instead. This change was made to better accommodate my specific zip ties. Additionally, I widened the zip tie slots to ensure they fit securely in place. Next, I added two loops on the front of the design for securing wires from the hot end, but unfortunately, I couldn't use them as planned due to space constraints caused by the lower block of the hot end hitting the IR sensor. However, this issue led me to add a loop at the back for tying off wires from my cooling fan and differential IR sensor. I also added a mount for the differential IR sensor, which was essential for its proper functioning. The entire design process took place in OnShape, where you can view or copy the files here: https://cad.onshape.com/documents/2e71f541012f0e76d3b84f6e/w/340e35434753e59a5d278079/e/a817b36487b914e0b47cfc91. The OnShape project includes mockups of a v6 hot end, the differential sensor, and the Titan. Despite these improvements, I still encountered some minor issues during the design phase. One of them was that the mesh didn't turn out perfectly for one of the fillets due to an unknown reason. Furthermore, my v6 is slightly longer than the model used in the design, which resulted in the IR sensor not reaching low enough; hence, I need to adjust its Z position for better alignment. Additionally, I had to add some pieces of cut-up gift card and double-sided tape on the left side to create a pad that would hit my endstop without losing any X due to the offset of the extruder. I lost almost 25mm of X with this design, which has me debating how to change things to get it back. I'm also considering removing the two front wire loops since they weren't needed in the end. Originally, my plan was to have the wires come off the hot end on the front but unfortunately, that wasn't possible due to space constraints. During printing, I had to rely on supports as without them, I would often experience layer shifts and unreliable prints. Although I'm aware of a few more minor issues with this design, such as the STL being upside down, it still serves its purpose effectively.