Single/dual Bowden extruders with mounting for Fabrikator or other RepRap

thingiverse

This is a complete bowden setup for a Turnigy printer that utilizes the existing parts from the direct drive that comes with the printer. You may need to source some additional components if you want a twin nozzle setup or are building this for another version of RepRap. A mount is included so that it can be securely and conveniently attached to the Fabrikator. Also, a replacement faceplate for the fabrikator using E3D extruders is provided. In addition to the printed parts and bits taken from the existing setup, you may need some of the following: (Quantities for single extruder) * 14 mm hobbed pulley * 13 mm bearing * 4 m3 x 20mm * 3 m3 x 8mm * Shaft with circlips and washers 5mm. If you can't locate one like this, a 5mm bolt with self-locking nut will do, cut to length. * Nema 17 or similar * E3D Chimera dual hot end, bowden version * E3D V6 single hot end, bowden version (or Chinese equivalent) Instructions: Dismantle the direct drive face plate and retrieve the hobbed wheel, bearing, and its two washers. If you're building a dual extruder, you'll need to find an additional source for these parts. Print the extruders. I've tested ABS and PET for suitable flexibility, but can't vouch for PLA being suitable...although it should be okay. Print one or two extruders, a left-hand and right-hand option are provided so you can ring the changes as to how you mount them. Thread a 3mm bolt through the tensioning holes and a captive nut at the other end. I used a bolt with a very wide head, but if you can't locate one of these, use a washer. The tension should be just right without tightening the bolt, but if you need more pressure, tighten up a bit. If the filament starts getting marked, it's too tight, slacken off until the filament comes through smooth. The plastic (ABS or PET) has enough elasticity to make a spring redundant, but by all means use a spring if you want! Tap the large hole to 9mm, you don't need a special tap. An ordinary bolt will do as it's only plastic. Screw in the Bowden attachment. Insert the bearing as per photo on the shaft with washers either side of the bearing (not essential). Secure with circlip. If you can't locate a shaft, just use a M5 bolt. Attach the stepper with 4 m3 x20mm bolts and you're done. Now print the appropriate mount, single or double and brackets. Now attach the extruder(s) to the printer using the mount which is affixed using 2 existing self-tappers as per photo. Use m3 x 8mm bolts to secure the motors. I mounted it at the back so the existing arrangement for the filament drums can be used as per original design. Now print the faceplate. The single is configured for the E3D V6 hot end. The double is for the E3D "Chimera" dual hot end. Affix as per photos and cable tie the wires to the printed attachments. Make sure everything is firm and rigid. Punch out the 2 neodymium magnets from the old hot end cover. Force these into the holes of the part fan mount. Attach the part fan with these magnets. If you're using 2 extruders, there's no longer a configurable power output for the fan on the Ramps board. You'll need a ramps 1.4 fan extender, search on ebay. Now all you need do is feed Teflon tube from the extruder to the hot end (x2) and you're ready to configure your machine for twin nozzles. You could struggle with the basic Marlin but Marlin X2, repetier or marlinkimbra are easier. Print Settings Printer Brand: Turnigy Fabrikator Printer: RepRap Rafts: Doesn't Matter Supports: Yes Resolution: 0.2 Infill: 40% Notes: I used PET and also tested ABS, these should be fine for flexibility. I haven't tried PLA but it should be OK.