Ender-3 filament runout & jam sensor / guide

thingiverse

Filament Runout Sensor - Jam/ Snag Sensor - Filament Guide =========================================================== Inspired by: All in One - Filament Jam - Cleaner & Runout Sensor by 3D-Muc This features two distinct components: 1. The runout sensor, based on laubed's design, attaches to 2. The jam sensor, my original creation The runout sensor guides the filament and can pivot around the jam sensor, which gets pulled in when the filament becomes entangled. Both switches are simply wired together in series with the runout normally open and the jam normally closed. I have included an STL file containing both parts closely situated to minimize required supports. I also included a single all-in-one combo design that I initially conceptualized but never printed, as I now prefer it in two separate pieces. The combo appears more challenging to print, yet I provided it for reference. If you already possess laubed's runout sensor, you can simply print my jam sensor and attach it with an extended screw or bolt. EDIT1: I lengthened the jam switch mounting hole to allow adjustment of when it activates without having to bend the switch arm. EDIT2: After utilizing this design for over a week almost constantly, I encountered my first false alarm. I discovered that PLA might not be the ideal material for this design due to its loss of elasticity after being compressed or bent for extended durations. Consequently, I recommend using PETG. I will remake it with PETG and report back later. I also plan to create a version utilizing PTFE tubes to reduce friction in the runout sensor holes, which would enable PLA to function as the primary material since the spring tab wouldn't be under continuous stress. EDIT3: I reprinted this design using PETG, resulting in improved performance compared to PLA. Additionally, I suggest mounting the runout sensor higher (utilizing the lower hole, similar to the third picture). I also developed a new version (v2) of the runout sensor that guides the limit switch roller more effectively, preventing it from getting alongside the filament and causing increased friction.