Leg-Room mod for BTT Smart Filament Sensor Mounting Bracket for Micro-Swiss Direct Drive Kit

prusaprinters

I spent a lot of time searching for a solution to allow me to use my Smart Filament sensor and my Micro Swiss Direct Drive without sacrificing z-height or having too long of a reverse bowden between the sensor and the extruder.The original was mostly held in place simply by the PTFE tube between the sensor and the extruder. I was never particularly comfortable with how loosely that original design was attached.This model which my remix is based off is a great way to mount your BTT Smart Filament Sensor directly above the Micro Swiss extruder on the X-Gantry of a Direct Drive modded Ender series printer. It added legs which clamp slightly under the stepper motor, locking it very securely in place. The fatal flaw was that these legs had a tendency to protrude too far below the motor and cause some friction with the x-gantry top wheels.My modification cuts out the center of both legs creating plenty of room for the wheels to function without making contact with the mount. Plenty of leg remains on each side to hold it securely.This was created using negative space modifiers in SuperSlicer. I'm not sure how well it will slice in another slicer, but if imported correctly it should appear as two cubes and during slicing any of the original model which contacts those cubes should be removed. You can confirm this worked correctly in the gcode preview of your slicer.I printed this with gyroid infill @ 20% and supports everywhere (mainly to help prop up the spaces I removed) but you could probably get away with only supporting on the build plate. The main thing is to support the slightly offset section where the sensor is screwed on.