e3d Titan extruder mount for Fusebox CoreXY

thingiverse

This is an updated design of the FuseBox CoreXY printer's print head. It features a Titan extruder from e3D for direct-drive printing with either 3mm or 1.75mm filament. The redesigned carriage is about 15mm wider than the original, which reduces the usable X-axis width, and the cage fan on the back similarly decreases the Y-axis travel distance by approximately 10mm. The extruder body has been moved inward as far as possible to minimize the width. To accommodate the belt heights, I raised the carriage platform. The hotend is now elevated well into the undercarriage. A fan duct cools the heat sink with directed airflow. I added a mount for the BLTouch Z-probe from ANTCLABS. It works quite effectively once I set the height correctly. The STL is designed to hold the pancake extruder motor from e3D, which is 25mm deep. You can use a larger motor, but you may need to adjust the cage. The openscad files are highly parametric to allow for this adjustment. The fan duct is tricky to assemble since it's located way up inside the undercarriage and the heater block gets in the way. The scoop goes around the heat sink fins. You can expand it wider to get around the heater block and then force it up onto the heat sink. You may be able to screw the heater on after the duct is attached, but I experienced trouble with this during my first prototype. This new design gives more room and should be easier to assemble, but I haven't tried it yet. The 50mm cage fan blows a lot more air than the original e3D fan. It's too much, really. To compensate, I narrowed the fan duct, but you may also need to slow down the fan or further restrict the airflow. Another option is to use the 30mm fan and mount it under the carriage. I haven't designed a part cooling fan for this print head yet. That will be coming soon. There are a couple of other tweaks to make, like better recessed nut captures. I'm printing with this head now, and it works well for me. I was worried it would be too heavy for this coreXY carriage, but it really is quite smooth. I printed mine in PET-G, but I expect PLA, ABS or Nylon would work as well. PLA might get a little melty on the fan duct, though. The fan duct has a small block under the scoop around the heatsink. This is a designed-in support structure and should be removed after printing. I did it this way because most slicers have difficulty providing support in just one location, and many of them fill up the fan duct where it's impossible to remove. You will need a 50mm cage fan for the heat sink blower, and a 22mm m3 or m4 screw to affix the fan duct to the carriage (optional).