X-Axis Rod Support for Wanhao Duplicator 4

thingiverse

A critical design flaw of the Duplicator4 lies in its 5mm x-axis rods at the front and rear, which are excessively thin. As a result, there's constant inward stress from the belts on these rods, and any bend they incur gets significantly amplified, leading to abrupt movements of the head assembly when sliding it manually. To combat this issue effectively, my customized device features a supporting rod that eliminates flexing in the original rod by installing an extra stabilizing mechanism at its mid-point. This solution was specifically tailored for perspex-cased Wanhao Duplicator4 but could be adaptable to other similar models. Please note that some stress is applied to this support, which is why it's crucial to print it with a considerable amount of strength – I opted for 4 shells and 50% infill. As you operate the head mechanism, you will become aware of flexing in the original rod. In this case, secure the support in place (using contact adhesive or foam tape) when the up/down motion is centered. Following that, apply a drop of oil to reduce friction levels. By implementing this modification, the feel of the head carriage on my printer underwent a notable improvement; however, there's still a slight bend present in my rods which will need to be addressed by completely disassembling and replacing them. I've made available two distinct variations of the support: 'Support short.stl' is specifically designed for attachment using industrial-strength foam tape – this was the method I employed myself. The foam tape utilized here measures 1.5mm in thickness. In contrast, 'Support Long.stl' is suited for direct adhesion with contact adhesive and consequently measures 1.5mm longer than its counterpart.