Nophead's power resistor heater block

thingiverse

The power resistor heater block detailed by nophead on http://hydraraptor.blogspot.com/2009/01/yet-another-quick-heater-hack.html is made from a kit obtainable at http://www.makergear.com/products/ceramic-heater-core, specifically the "Power resistor heater kit". This design replaces nichrome found in other hot end constructions and functions as a heating element to heat an aluminum block surrounding the heater barrel. It is installed on an oversized Mini Mendel Huxley (with just enough space at the X carriage's bottom, a new one may be made once printing starts). Nophead's picture can be used if a custom design is made, or the license changed to his preference. Thingiverse occasionally flips pictures upside-down; uploads will be reattempted. To assemble, an aluminum block of at least 19x19x8mm (mine: 20x20x13mm) is required. Drill a 5mm hole on one side for the heater barrel through any dimension using a drill press if available (as mine was manual). Tap it with a 6mm, 1mm pitch tap. Next, create a 7mm hole along the long dimension for the resistor and drill a third hole just large enough to embed the thermistor. Insulate leads carefully with the provided PTFE tubing and polyimide tape before connecting the resistor and thermistor to the extruder controller.