Flexible Shaft Direct Drive for Ender 3 & CR10S

thingiverse

UPDATE NOTICE: I've Abandoned This Project Until Further Notice. I've spent a lot of time, effort, and probably twice the price of a Nimble trying to get this thing to work effectively, but unfortunately, it still can't function due to the flexing of the core considerably negating the applied retraction. As a result, I'm abandoning this project until I find something suitable that makes it work effectively. I've uploaded my recent side-mounted stepper-mounted design, which uses the speedometer cable below, and the design allows the speedo cable to be cut down to 500mm. However, I won't be supporting this any further. The additional uploaded files are purely for anyone who may want them for future reference. Cable Link: https://www.amazon.co.uk/gp/product/B00ANLKCP4/ref=ppx_yo_dt_b_asin_title_o02_s00?ie=UTF8&psc=1 4-5mm Coupling Used in Side-Mounted Version: https://www.amazon.co.uk/gp/product/B07PC3RV79/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1 Link to Video of Side-Mounted Speedometer Cable Design: https://youtu.be/p3_mwdY8ywI This is a Direct Drive Extruder design that uses a flexible drive shaft to reduce the weight of the Extruder Head. It works as described, but I'm leaving the status as WIP for now for further print testing. I'll upload an installation guide when complete. BOM: 1. These are the actual components I've used; you can find less expensive options with longer delivery times if that suits. https://www.amazon.co.uk/gp/product/B07PB2QXZK/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1 https://www.amazon.co.uk/gp/product/B07CN5SGJM/ref=ppx_yo_dt_b_asin_title_o05_s00?ie=UTF8&psc=1 https://www.amazon.co.uk/gp/product/B07PK7HL8F/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1 https://www.amazon.co.uk/dp/B01LWIHJ90/?coliid=I50UP45DIRN2Q&colid=1HZG88GFJC8J7&psc=1&ref_=lv_ov_lig_dp_it Print Settings: 1. All things except the flex drive bracket will print without supports. 2. I've printed the components at 40% infill, 3 perimeters with Tronsky Orange PETG & PrimaSelect Light Blue PETG. Average printing temp was 240C with a bed temp of 70C. 3. I've uploaded 2 versions of the Flexible Drive bracket. One is an additional support pad to allow for interim supports in your slicer to reduce the likelihood of the PETG-based supports warping. 4. I've included some sacrificial layers to various holes in most parts to aid bridging when printing. These will require cleaning out prior to assembly. Operation: Due to the flexing of the shaft, there are a few quirks with this thing. I'm still testing and have no specific overall conclusions at this time. 1. Retraction - Due to the flexing of the shaft, the retraction needs to be higher to compensate. Therefore, although a high retraction is set in the slicer, the actual received retraction at the extruder head is still much lower. I'm still testing this. What Next? 1. Reducing the overall weight of the extruder assembly, perhaps using a single 5015 duct arrangement and single body duct/bracket if achievable. 2. Extensive slicer tweaking to offset the flexing of the drive shaft.