Ender 5 Orbiter 1.5 Direct Drive Bora Extruder Mount

thingiverse

This is a remix of Leo_N's excellent Bora hotend cooling mount for the Ender 3. This remix is based on the earlier version of the Bora that used the stock parts cooling fan and a Mistral E cooling duct. I've also copied the mount from lorinczroby's v1.5 mount https://www.thingiverse.com/thing:4758694. You will need the original "Bora_Blower_Duct" from the Bora project, this thing only includes the updated mount for all of the ducts. The goal for this mount was to keep the weight low, keep the mass of the Orbiter stepper motor in line with the X axis rollers, as well as have it work with the stock Ender 5 hotend. So far it seems to be working well for the benchy (printed at 75mm base speed). I ran a ~31mm length of bowden tubing between the output of the Orbiter and the hotend, but this is based on using a "PTFE Hotend Fix" ( https://www.thingiverse.com/thing:3203831 ). If you aren't using the hotend fix, you SHOULD, it cleans up the bowden to nozzle gap nicely. In any case, you will need do some trial and error to get the right length of bowden tubing between the bottom of the Orbiter and the hotend for your particular setup. I originally used the Mistral E duct, but there's often a little variation in nozzle length, and ended up using McGybeer's remix ( https://www.thingiverse.com/thing:3855884 ) that shaved 1mm off the bottom of the duct to get more clearance on my Ender 5. Notes on the conversion: 1. The cable that comes with the Orbiter (I got mine from Mellow, I think they're all from the same source) was too short to cleanly route it back to the controller board. I ended up using 4 male/male Dupont cables to patch the new cable into the original extruder cable to get enough length. 2. The cable the comes with the Orbiter requires that "REVERSE_E_MOTOR_DIRECTION" be defined in Configuration.h for Marlin. But my original extruder cable swapped the 2 inner wires, if you patch in the original cable, you can take care of the reverse direction there without messing with the firmware. 3. This was my first time messing with vref on my printers, and that little pot is super, super sensitive! It was fiddly landing it just under .5V 4. Using the Creality v4.2.7 board, it seems there is no way to set the max current - the #define declarations in the Marlin source were all ghosted out in my IDE, indicating that this cannot be controlled via firmware in the Creality board. From what I read, the standalone Trinamic driver implementation on that board doesn't expose this feature. Just in case my IDE was confused, I updated the HAS_TRINAMIC_CONFIG section of Configuration_adv.h and set E0_CURRENT to 500. But I expect it to have no effect - the motor seemed to be running pretty cool on this benchy. Extrusion looks cleaner than before, though it was already pretty clean. Corners seem like they might be a little less crisp printing the 30mm extruder calibration cube at 75mm/s base speed - that extra 150g has to show up somehow. I haven't dug into retraction tuning yet, going with 1.5mm at 25mm/s seems to do okay with this new PETG filament I'm using. This was my first spool of PETG and I'm not sure how hard it would be to tune away the stringing the way I could with PLA+.