Ender 5 Direct Drive Stock Hotend and Extruder

thingiverse

This is a direct drive conversion for the Ender 5, Pro and Plus, using the stock hotend and extruder assembly. The part cooling relies on a superior 5015 blower, outperforming the stock part cooling blower in every way. The duct and outlet nozzles have been optimized through CFD analysis to deliver exceptional cooling performance. This same geometry has been used in previous part cooling solutions with impressive results. The hotend fan is the standard size 4010 axial fan, but it's being utilized in a more effective ducted arrangement to direct cooling air over the heatsink before exhausting it out sideways, avoiding uncontrolled part cooling. Internal vanes are present due to initial investigations on maximizing the effective flow from axial fans conducted by Alex Kenis. Check out his video on the subject here: https://www.youtube.com/watch?v=SX-okOHvh1Q&t=1376s Once assembled, you can access the hotend by removing three screws - two from the shroud and one that fixes the 4010 fan to the mount. The entire assembly lifts off in a single piece, leaving the mount and extruder assembly intact. Equally, remove three screws and the entire extruder assembly lifts clear should it be required. I recommend printing the components with 3 to 4 walls and 15-20% infill. All parts are designed to print with minimal support from the buildplate only. Setting an overhang angle of 60° should avoid any unwanted placement. Both the stepper mount and the shroud print with zero support. Print in the orientation downloaded. The parts are held together with M3 screws into heat set inserts. All the holes are sized at 4.1mm to suit the common, inexpensive M3 x 5mm long brass inserts readily available online. The complete hardware list is: 7x M3x5mm long heat set threaded inserts - 4 in the shroud and 3 in the mount. 1x M3x22mm + 1x M3 Nyloc nut to hold the 5015 blower to the duct. 2x M3x20mm + 2x M3 washers to secure the duct to the shroud. 3x M3x15mm to secure the 4010 hotend fan to the shroud and mount. 1x M3x12mm to secure the shroud to the mount. 2x M3x15mm, 1x M3 x 12mm, and 3x M3 Nyloc nuts to secure the stepper mount to the mount. 2x M3x8mm dome headed screws to secure the mount to the Creality X carriage. You will also need to replace one of the roller bolts with a M5x25mm socket head screw. NB: All screws are socket head unless otherwise stated. 5-2-2020: BLTouch added. The correct mount is identified with the BLT suffix. Offsets are X -42, Y -17.