Flexion Extruder adaptor for Monoprice Maker Ultimate and Wanhao Duplicator 6

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# Flexion Extruder Upgrade for Monoprice Maker Ultimate and Wanhao Duplicator 6 This upgrade allows you to mount a Flexion Extruder on an MMU (a rebranded Wanhao Duplicator 6+). This is the version that has dual gantry rods for both X and Y. The completed upgrade mounts the Flexion Extruder below the gantry as shown in the main photo. This puts the nozzle approximately 35mm below the original nozzle and a bit in front of the gantry. The final build volume remains unchanged in X (200mm), about 9.1mm less in Y (190.9 mm) and 35mm less in Z (135mm). What you gain for the sacrificed build volume is the capability to print very soft material (Flexion X60, Shore 60A TPU filament). ## Materials Needed The Flexion kit was not designed for this printer. As such, we need to print mounting brackets and procure a few parts. All of the links are valid as of the time of this writing (May, 2019). The Amazon links are to "smile.amazon.com" whereby you can designate a non-profit to receive donations based on your purchases. ### Heater Block The heater block that comes with the kit requires either screw-in or glass bead thermistors. The MMU uses a PT100 temperature probe that does not fit in this block, and the PT100 input on the controller board doesn't like working with normal thermistors. An E3D V6 (or compatible) heater block works. The block needs to have M6 threads for the nozzle and heat break barrel, and a 3.1mm hole for the PT100 probe. The probe is held in by a set screw (grub screw). I found a pack of 5 clones of the V6 on Amazon [WINSINN V6 Heater Block Sensor Aluminum for HT-NTC100K PT100 RepRap Bowden J-Head V6 3D Printer Extruder Hotend](https://smile.amazon.com/gp/product/B077MGZ7K8). ### Screwdrivers Also, do yourself a favor and get a set of metric hex screwdrivers. I got this set: [Eklind 92400 8 Piece Hex Key Series PSD Precision Screwdriver Set](https://smile.amazon.com/gp/product/B002C5FH0E). For this project you will need 2.5mm, 2.0mm, and 1.5mm (the 1.5mm is only used for the hot-end set screws). ### Screws You will need a selection of M3 cap head screws and hex nuts. Specifically: * 5 6mm screws * 6 8mm screws * 4 10mm screws * 2 12mm screws ### The Parts To Print The parts to make this modification come in two categories: High-strength parts that need to withstand higher temperatures, and parts that just need the right size & shape. I printed all of my parts on an Ultimaker 3 using Nylon (white) for the high-strength/high-temperature parts and Tough PLA (green) for the other parts. ### High Strength Parts * Frame.stl: This is the main bracket that attaches to the XY gantry. * LeftLeg.stl, RightLeg.stl: Connects the Frame to the stepper motor, cooling block, and hot end. * BackBracket.stl: Provides additional support to the back of the stepper motor and a connection point for the print-cooling fan bracket/funnel. * FanBracket.stl: Print cooling fan bracket and funnel. ### Other Parts * TopBracket.stl: Mounts to the top of the gantry and supports the circuit board. * TopCover.stl: Covers all of the cables and provides routing for filament and feeder tube * ZLimitSpacer.stl, ZLimitClamp.stl, JamNut.stl, Knob.stl: Provides an extension of the Z-limit switch actuator * YLimitSpacer.stl: Provides an extension to press the Y-Limit switch. The pictures above show the orientations in which I printed these parts. ## CAD Files I've included the design file in STEP format. This includes a model provided by Flexion around which I built the parts needed. The stepper motor on the MMU is shorter than the one shown in their file, so the one in here is re-dimensioned to be accurate for the MMU.