Ultra Compact Opto Z-Probe for Mendel with Diamond Nozzle

thingiverse

This is a highly compact Z-Probe assembly featuring opto-barrier design tailored specifically for my vertical x-axis with multicolor diamond nozzle (http://www.thingiverse.com/thing:1415013). However, it can also be installed on other carriages. It connects to the carriage via just one M3 screw positioned very close to the nozzle tip. The main advantages of this design are: Compact and lightweight structure Only one connecting screw required Servo can be easily replaced by simply removing one cable tie Very close proximity to the nozzle, approximately 1 inch Improvements / Modifications Version 2-2 First release Version 2-3 Opto-probe replaced with shorter signal path Added space for SP90 servo with cable on the side (instead of rear end) Slight weight reduction Post-Printing Bill of Materials You will need the following printed parts: 1x Probe V2 body 1x Probe-Bar Get additional components: 2x screw M3 x 30mm 4x screw M3 x 12mm 1x screw M3 x 40mm 8x nut M3 2x nut M3 self-locking 1x screw M5 x 50mm 1x nut M5 1x nut M5 self-locking 1x Opto-Probe on PCB (e.g. Chinese product) 1x Servo SP90 (e.g. Chinese product) 30 cm of thin isolated flexible cables 6cm shrinking tubing, fitting the cables 1x cable-tie 6mm x 180mm A first sketch of the idea. Preparing the Probe Pick up the M5 x 50mm screw. Use a saw to cut off the screw's head. Use a file to shape about 20mm of one side of the screw. Dimensions approximately 4,2mm x 2,8mm. Use a saw to cut away about 8mm of the thread and form a point at this end. Overall length approximately 4,2 cm. Finally your probe should look like this Probe Bar Assembly Put the M5 nut into the printed probe bar and screw in the probe. Use the self-locking m5-nut to fix the probe in place. This is the probe bar assembly Opto-Barrier Modification Due to the compact design, the Opto-barrier and PCB must be separated. Use a solder iron to unsolder the barrier and remember which pin goes to which pad. Connect a wire to each pin and protect it with a small piece of shrinking tubing. Solder the open wire-ends to the corresponding pads of the PCB. Mount the Opto-barrier and the PCB onto the printed probe body using M3 screws and nuts Place the wires in the trenches of the printed body part. Attach Probe Bar to Probe Body Put two M3 nuts into the foreseen pits of the probe body. Attach the two M3 x 30mm screws. They will act as guidance for the probe bar. Probe Retracted Probe Extended. The M3 nuts acting as stop are missing here. Final Tips You'll need the M3 x 40mm screw to attach the probe assembly at the x-carriage. Do that before mounting the servo with the cable-tie because the screw is situated underneath the servo! Before you connect the Servo to your controller make sure that it provides enough power for the servo - or you can damage your controller! Better: Use an external powersource.