Stephs Direct drive extruder for i3 Rework/Wilson

thingiverse

This extruder is engineered for use on 4 screw style carriages employed in i3 reworks and Reprap Wilson devices. It incorporates the E3D V6 1.75mm hotend, which uses a PTFE tube as a guide. This design accommodates the MK8 drive gear; however, if desired, a version tailored to MK7 gears can be created upon request. Additionally, an upgraded jhead version will be provided. A total of two fan mounts are included; although fan designs have yet to materialize, users may either produce their own or contribute to the collective effort. Support structures are not incorporated into the model, necessitating reliance on slicer-generated supports. It's possible that integrated support structures might be introduced later, though anecdotal evidence suggests enhanced success with supports created through slicer programs. Revision: I have initiated the development of a modified version featuring built-in supports centered on the hinge. Success of this innovation is yet to be confirmed. Version 2 Revision: Upon further evaluation, I've observed that these integrated supports are effective. An enhancement has been made to include support for the fan hinge flange. The need for supplementary support structures is now diminished, though still advised as a precautionary measure. Changes inherent in Version 2 include: The extruder height was elevated by approximately 2.3mm. This alteration enabled a thicker bearing support, strengthening the component. Modifications were made to increase the 'washer' portion of the bearing holder, enhancing ease of printing. The clearance surrounding the bearing on the idler has been optimized to 0.5mm. An extension of 3mm was implemented for the finger tab. Consequently, due to increased extruder height, motor screws have been counter-sunk for enhanced assembly accessibility. Tolerances around the motor flange have been set at a looser 0.2mm for uncomplicated printing. The clamp used in hotend installation now boasts slightly reduced tolerance (0.1mm instead of 0.2). Further optimization to Version 2 resulted in slight changes and rectification of previously identified errors. A modified version was initiated (Version 2a) featuring slight modifications in tolerances along with corrections for previous issues and bugs. The hinge support is now designed to be easily removable, easing post-printing operations. Upon subsequent revisions (Versions 2b & 2c), focus shifted toward refinements in support integration. The Version 2d iteration introduced a notable change by incorporating a bevel on the no-PTFE version's filament path. This feature affects flexibility in PTFE tube placement within assembly confines, necessitating adjustments for compatibility purposes. Please exercise caution when handling high-strength materials and take into consideration recommendations for optimal material choices. Printing Guidelines: Preferred filament: ABS or PETG Layer height preference: 0.1mm Infill percentage recommendation: 25% Important Notes: Support is necessary for proper extruder functionality. It is advisable to use high-temperature filaments for successful assembly. Advised Printing Method: 0.1mm layer thickness. Ensure Supports are enabled for the entire model. Post-Assembly Procedure: Remove support structures and drill necessary holes For assembly purposes, install the hotend first. Prioritize following E3D directions to guarantee secure seating of the PTFE tube within the hotend. Upon assembly completion, inspect motor mounting screw requirements with a maximum of two washers for compatible steppers; avoid over-tightening to prevent stepper motor thread damage.