Ender 3 Filament Roller Wheel & Pin (Improved)

thingiverse

I had two issues with the original: The first was the wheel had a very shallow groove that the filament kept not aligning with. I often found my filament rubbing on the side of the wheel instead of the center groove. This new wheel is the same size but has a smoother, slightly deeper groove that should keep the filament centered. The other issue was the split-end pin was very fragile and broke easily. In keeping with the true spirit of no hardware needed, I didn't want to just replace it with a bolt & nut but instead wanted to design a very simple pin that anyone can print easily. Print the wheel flat on its side - no supports, a couple walls, 5% infill is fine. If you change the top/bottom layer pattern to concentric, it will look extra nice! Print the pins with Spiral Mode aka Spiralize Outer Contour with enough Initial Bottom Layers to make the cap solid (I used 10). Turn on a brim if you have trouble with bed adhesion. Each pin should print quickly this way - 3 min each for me. Pin2 should slide snug inside Pin1. I have provided 2 versions of Pin2 in case your tolerances are off, or you can try rescaling Pin2 yourself. Do not scale Pin1, if you make it larger it won't fit the holes. If you just don't want to trust the strength of a single wall from spiral mode, you can always print Pin2 solid and use a dab of glue to ensure it won't slip out of Pin1. Assemble on the original arm.