Lulzbot Mini Printhead Wiring Clip

thingiverse

Updated 2/11/17 - Moved clip over 0.7mm to account for printer assembly tolerances. Should have plenty of clearance for small extrusion gear. Please make sure you use the latest STL file! Enjoy! The Lulzbot Mini is a very powerful printer that can deliver impressive results, but one annoying issue that some users encounter is having to cut and replace two zip ties every time they switch between the standard printhead and the flexystruder. To solve this problem, I designed a simple yet effective solution - a small clip that holds the wires in place using M3 screws and existing zip tie holes. This clip eliminates the need for modifications to production parts and makes it easy to switch between print heads without any hassle. To complete this project, you will need: 1 x Printed Clip made from ABS/PETG/HT or other high-strength/high-temperature materials 2 x M3 x 10mm Socket Head Cap Screws (available at McMaster-Carr) 2 x M3-0.5 x 3.8mm length heat stake inserts (available at It Works 3D) 1-2 small zip ties (only needed once) Tools: * A 5mm drill bit * A soldering iron * A 3mm and 5mm hex key Print Settings: Printer Brand: LulzBot Printer: Mini Rafts: No Supports: Yes Resolution: 0.2 Infill: 20% Wall thickness: 1mm Standard ABS print settings should work fine, but for the best results, use a brim to minimize warp. Post-Printing: Step 1: Ream Holes Reorient the part on the print bed so that the clip cylinder is vertical. Print with supports and a brim. Once the part has finished printing, notice it has two holes that need to be reamed to 5mm diameter for proper heat stake insertion. Use a 5mm drill (or English equivalent) to ream the holes if necessary. Step 2: Use Heat Inserts and Stake Gently press the inserts into place as shown below. Use a soldering iron to heat the inserts until they press into the part and are flush with the surface. See images for reference. Heat stake both inserts for a secure fit. Step 3: Remove Old Tool Head Follow steps 1-8 from the Lulzbot OHAI page to remove your existing tool head: https://ohai.lulzbot.com/project/flexystruder-install-lulzbot-mini/accessories/ Once step 8 is complete, your print head should be completely removed and the old zip tie wire retainers should be removed. Step 4: Install Wire Clip The new clip installs in the same place as the zip ties once threaded through. See images below to align the holes with the inserts. Slide the clip onto the X carriage and use two M3 - 10mm SHCS to attach it. Note that the lower screw should be installed from the front, while the upper screw should be installed from the back. Step 5: Install New Print Head Using the Lulzbot OHAI install guide, install whatever printhead you want to use: https://ohai.lulzbot.com/project/flexystruder-install-lulzbot-mini/accessories/ In step 10, instead of using zip ties to install the cable, press the wiring harness into your new clip. Use 1-2 mini zip ties above the clip to wrap around the panduit corrugated cover. These can be left installed forever. Step 6: Done Enjoy! You should no longer need to cut or buy new zip ties to swap print heads.