Ender 3 Lightweight DD Overhaul & Linear Rail

prusaprinters

<p>This is my complete overhaul for the Ender 3's X axis. I used this to get my (currently) world record bedslinger #speedboatrace benchy at only 4m 48s.</p><p>After trying other people's designs and having issues or bad performance as they always lacked something or another, I finally decided to design my own X axis system.</p><p>I managed to push my printer up to 40kmm/s^2 accelerations at 360mm/s, with the bottleneck being my E3D High Torque steppers (I don't recommend, buy LDO 2504AC instead).</p><p>I'll be sharing the STEP file along with the STLs, and I would love to see the community's upgrades for my design!</p><p>This project requires:</p><p>Tools:</p><ul><li>Soldering Iron / Insert Tool</li><li>Hex keys</li><li>Pliers</li><li>Tubing cutter / exacto knife</li></ul><p>Hardware &amp; Parts:</p><ul><li>&nbsp;MGN12H 300mm rail</li><li>Phaetus Rapido HF Hotend</li><li>28mm PTFE tube</li><li>Orbiter v1.5 (might upload other versions for other extruders in the near future)</li><li>2x 5015 blower fans (I use 12v GDSTime fans, they run great at 24v and move a lot of air)</li><li>25x10mm fan or 40x10mm fan (25mm is lighter and more than enough cooling for the Rapido)</li><li>BLTouch (Not required)</li><li>ADXL345 Accelerometer (Not required)</li><li>2x M3*6mm screws (for the accelerometer, not required if not using one)</li><li>15x M3*8mm screws</li><li>4x M3*10mm screws (2 of which for the BLTouch, not required if not using one)</li><li>2x M3*14mm screws</li><li>4x M4*18mm screws</li><li>4x M2.5*8mm screws (Included with the Rapido Hotend)</li><li>2x M3 Nuts</li><li>6x M3 inserts (Designed for these: <a href="https://www.aliexpress.com/item/1005002615923810.html">https://www.aliexpress.com/item/1005002615923810.html</a> OD 4.2mm H3mm)</li></ul><p>Printed Parts:</p><ul><li>Mount</li><li>Duct L</li><li>Duct R</li><li>25mm Fan Duct / 40mm Fan Duct, according to your hotend cooling fan size</li></ul><p>Print settings and orientation:</p><p>I recommend 25% Gyroid infill, 4 walls &nbsp;(+ alternate extra wall for mount), no supports, 0.2mm layer height, 0.5mm line width.</p><ul><li>Mount: Align to this specific face:<img src="https://media.prusaprinters.org/media/prints/128229/rich_content/6d4d9674-5ec5-4c22-8646-5631eff6b105/screenshot-2022-02-02-101153.jpg#%7B%22uuid%22%3A%2236aaa23a-a163-4429-96d5-6dc044be8e5e%22%2C%22w%22%3A1295%2C%22h%22%3A897%7D"></li></ul><figure class="image"><img src="https://media.prusaprinters.org/media/prints/128229/rich_content/8c8195fc-a7ce-4c8b-ba42-d4eef8ff4c69/image.png#%7B%22uuid%22%3A%224134277c-6dbd-4b73-aafd-b14b4f0c9cb1%22%2C%22w%22%3A710%2C%22h%22%3A727%7D"></figure><ul><li>Ducts L and R: <img src="https://media.prusaprinters.org/media/prints/128229/rich_content/43bc318e-353e-4390-b932-4b5b5f2d0c9d/image.png#%7B%22uuid%22%3A%227ab60694-8db6-4c11-8a72-18aab5a78ea1%22%2C%22w%22%3A999%2C%22h%22%3A850%7D"></li><li>25mm / 40mm duct: <img src="https://media.prusaprinters.org/media/prints/128229/rich_content/d1fd9894-d2bc-423a-8f96-730bd0eafaf2/image.png#%7B%22uuid%22%3A%226eaad28b-58ae-41f0-bec7-b6f795679657%22%2C%22w%22%3A1009%2C%22h%22%3A866%7D"></li></ul><p>&nbsp;</p><p>Build instructions:&nbsp;</p><ul><li>Insert 6 M3 inserts to the Mount at these points: <img src="https://media.prusaprinters.org/media/prints/128229/rich_content/4baf56df-6387-4927-b57e-e78b9f592c14/image.png#%7B%22uuid%22%3A%223a24e84f-57cf-43c5-84a0-32d783e3669a%22%2C%22w%22%3A1347%2C%22h%22%3A957%7D"></li><li>Cut out the built-in supports for the belt slots: <img src="https://media.prusaprinters.org/media/prints/128229/rich_content/c7cfd164-b4fd-4396-bf73-dcca07fd53b2/image.png#%7B%22uuid%22%3A%2232336911-e22d-4729-bf9d-3f2fb025ea10%22%2C%22w%22%3A1166%2C%22h%22%3A1026%7D"></li><li>Mount the linear rail to the front of the 2020 extrusion. You can use every second screw hole:</li></ul><figure class="image"><img src="https://media.prusaprinters.org/media/prints/128229/rich_content/d0f077a3-7579-419c-ad28-a721fffe6dfd/screenshot-2022-02-02-100723.jpg#%7B%22uuid%22%3A%22f336725b-dd33-4895-9de1-464473918b9f%22%2C%22w%22%3A1773%2C%22h%22%3A622%7D"></figure><ul><li>Mount the Mount printed part to the linear rail using M3*8mm screws and connect the belt (red): <img src="https://media.prusaprinters.org/media/prints/128229/rich_content/03d3f5a5-bccd-4161-bce1-dab51987c401/image.png#%7B%22uuid%22%3A%22d934e2b9-a886-4a3c-94a6-4b3468ccec58%22%2C%22w%22%3A970%2C%22h%22%3A675%7D"></li><li>Mount the hotend fan to your desired duct (25/40mm with 2x M3*14mm screws) and put in on the Rapido: &nbsp;<img src="https://media.prusaprinters.org/media/prints/128229/rich_content/b5c93adc-7d41-49b3-9591-2ab40d86f485/image.png#%7B%22uuid%22%3A%22cf47b2f6-9662-4b53-8a46-d0445ae99186%22%2C%22w%22%3A1126%2C%22h%22%3A857%7D"></li><li>Mount the Rapido hotend and cooling fan using 4x M2.5*8mm screws. make sure the cable is going in the direction as shown in blue:<img src="https://media.prusaprinters.org/media/prints/128229/rich_content/f7691954-7ada-44ce-be7d-1ae5eba01dc2/image.png#%7B%22uuid%22%3A%22f12aed97-13ce-419b-b7fc-7b4f036343aa%22%2C%22w%22%3A888%2C%22h%22%3A918%7D"></li><li>Insert a 28mm piece of PTFE tube into the Rapido (red), and screw in the Orbiter (2x M3*10mm, blue): <img src="https://media.prusaprinters.org/media/prints/128229/rich_content/63d5f184-7230-42f4-b84c-53514be9536b/image.png#%7B%22uuid%22%3A%2234d1da1f-4a54-4013-9885-bb230ab2a129%22%2C%22w%22%3A707%2C%22h%22%3A978%7D"></li><li>Mount the 5015 fans (4x M4*18) and BLTouch (2x M3*10 + 2x M3 nuts) with the screws as shown. The M4 screws thread directly into the plastic: <img src="https://media.prusaprinters.org/media/prints/128229/rich_content/1796f4eb-5d9c-4957-bc5a-992d98902185/image.png#%7B%22uuid%22%3A%22e6b3e278-bea8-43e7-b404-85ac4a93a1ad%22%2C%22w%22%3A1148%2C%22h%22%3A917%7D"></li><li>Mount the Accelerometer (2x M3*6mm, red) and the 5015 fan ducts (4x M3*8mm, blue): <img src="https://media.prusaprinters.org/media/prints/128229/rich_content/189f4569-4e7e-472f-9685-6feb8900756b/image.png#%7B%22uuid%22%3A%225fecde8d-7333-4e27-b1c9-007a5b9de229%22%2C%22w%22%3A862%2C%22h%22%3A948%7D"></li></ul><p>Tighten your belt and all done!</p><p>General Settings:</p><p>BLTouch offset: ~3mm Z (calibrate exactly manually), -49mm X, 0mm Y</p><p>Pressure advance: 0.032, smooth time 0.04s (also need to calibrate exactly yourself)</p><p>Fan speed: 30% or so for most stuff, 50% if extra cooling is needed. 100% basically exclusively for speed benchies :)</p><p>Klipper things:</p><p>[bltouch]<br>samples: 2<br>speed: 8<br>lift_speed: 20<br>samples_tolerance: 0.015<br>sample_retract_dist: 1.6<br>samples_tolerance_retries: 4<br>pin_move_time: 0.65<br>stow_on_each_sample: False</p><p>[safe_z_home]<br>home_xy_position: 166,117.5<br>speed: 240.0<br>z_hop: 5<br>z_hop_speed: 20.0</p><p>[bed_mesh]<br>speed: 200<br>horizontal_move_z: 6.5<br>mesh_min: 10,15<br>mesh_max: 200,225<br>probe_count: 5,5</p><p>[input_shaper]<br>shaper_freq_x: 58.2<br>shaper_type_x: mzv</p><p>&nbsp;</p><p>*input shaper should also be calibrated manually, i'm giving my settings as a general guideline.</p><p>Final setup:<img src="https://media.prusaprinters.org/media/prints/128229/rich_content/31304209-7ecd-48f3-8deb-8feec3d242c6/whatsapp-image-2022-02-01-at-212332.jpeg#%7B%22uuid%22%3A%22816649cc-8443-4d95-a825-75b1d71cb745%22%2C%22w%22%3A1600%2C%22h%22%3A900%7D"></p><p>Happy printing!</p>