E3Dv6 mount on Cyborg belted Extruder flexible capable

thingiverse

I added a new version "v3" with a corrected filament inlet, now centered and filleted. The extruder is tested now and works excellently with both materials, standard filament AND flexible filament. I added a video of the extruder successfully printing very soft Ninjaflex (https://www.youtube.com/watch?v=FvWWlDzHRTk). For soft filament, don't fasten the idler screws too much, the filament must not get "squeezed". I remodeled the great Cyborg belted extruder by Xeroside (thanks a lot!) in two ways: 1. I added a mount for a standard E3Dv6 extruder. So it becomes a complete direct extruder. 2. I remodeled the outlet shape of the inner filament path to be more in the middle of the path and closer to the hobbed bolt and pressure bearing. With this modification, it is also possible to print flexible filaments! 3. The pressure bearing arm was adapted to fit the main body modifications I attached a video from a successful extrusion test with Ninjaflex filament: https://youtu.be/lRwZNhWAmZ4. Be aware that the pressure bearing tension, adjusted with the two spring screws, must not be too high for flexible filaments. I mounted this extruder by using the rear screws of the stepper motor. Printing: You need supports only for the main body. Please assure that there are no supports in the two mounting holes for the extruder-locking screws. You can accomplish this by raising the x-y-distance of the support structures to 1,5 - 2mm. Or, in S3D, you can remove these supports manually. The two other parts can be printed without any support. Mounting the E3D: You need two screws M3x25. Cut a piece of bowden tube to the exact length to reach from the hole in the main body, in which it inserts about 3mm, to the whole length into the extruder. Example shown in the pictures. Insert Tube and extruder together into the main body, then slide the locking piece into the main body and fasten it with the two 25mm screws. You have to assemble the hotend BEFORE the extruder bolt and the wheels, otherwise it is not easy to reach the screws. You find the other mechanical parts needed in the description of the original thing from Xeroside. I printed the test version in PLA, testing with nozzle temperatures up to 220°C, and the E3D part in contact with the main body didn't get too hot. But if you want to be sure, print it in ABS. Advantage of a GEARED direct extruder: Previously using the great Flexion extruder, I discovered that if you are printing PLA with it (or any DIRECT extruder), the extrusion may become irregular in the way that the stepping of the extruder motor may become visible in the printed part. A solution might be using a TMC2100 with 1/16 steps interpolated to 1/256, but if this is not possible, the geared extruder reduces the size of each step significantly!