ENDER 3 / CR-10 Direct Extruder

thingiverse

I scrapped the previously announced major overhaul because its drawbacks far outweighed relatively minor improvements, so here are some iterative tweaks for the first release. This Thing is still a work in progress. I tested the design and it works well for me, but I'm not satisfied with the current wire management setup. Description is also very much WIP. Check out this thing if you want to use your own extruder: https://www.thingiverse.com/thing:3369418 ###Design Goals A simple direct extruder that's compatible with widely used fan ducts and requires a minimal amount of easily obtainable additional or salvaged parts. ###Compatibility If you've found it working with others, please let me know and I'll update this list. It works well with: * **Hero-Me** in stock or single 5015 blower configuration with the wire guide chopped off (I'll add a slightly higher base for the dual 5015 version soon) * **Bullseye** with the wire guide chopped off ###Bill of Materials: * 2x **608 bearing** (2RS recommended) * 1x **623 bearing** (2RS recommended) * 1x **ca. 20x8x1 spring** (stock extruder or bed springs should do the job, I use one of the typical yellow bed upgrade springs) * 1x **M8x50 bolt** (to be hobbed as drive gear: https://reprap.org/wiki/Making_a_Hobbed_Bolt) * 1x **M8 blocknut** (or 2 nuts counter each other) * 1x **PC4 M10 bowden coupler** (like on the stock hotend) * 1x **M3 x 30 bolt** (may vary depending on the spring you use) * 1x **M3 x 10 bolt** * 1x **M3 x 6 bolt** * 1x **M3 x 22 bolt** * 2x **M3 x 16 bolt** * 3x **M3 nut** * 2x **M3 washer** * 1x **M4 washer** ###Print Orientation & Supports **Gears:** Flat sides down, no supports. **Body:** Back side (where gears attach) down, full supports **Idler:** On its side, full supports **Spacer:** Laying flat ###Miscellaneous Make sure to get the length of the remaining PTFE tube just right and have it gripped tight by the couplers. The PTFE tube is a structural part; if you experience flexing of the extruder during extrusion, a sloppy tube connection is likely to be the root cause. Some connections have quite tight tolerances; expect to do some sanding to get everything moving smoothly if you haven't tuned your line width excessively. Adjust the height of the included M8 spacer to fine-tune the alignment of the hobbed bolt. It works well in PLA, but you'll need to keep an eye on the motor temperature as it may soften the PLA. If you experience high temperatures, a heatsink on the motor is highly recommended.