zero friction top side optical filament sensor (for CR10S)

thingiverse

I've been utilizing my top filament sensor (https://www.thingiverse.com/thing:3431821) without any problems so far, but I encountered a significant issue with the mechanical switch contact within the sensor. It creates an excessive amount of noise when the filament passes through it, and this noise is even more pronounced during retraction cycles. To eliminate this annoying noise, I designed a fully optical replacement that completely eliminates contact between the filament and any metal components. Instead, the filament runs smoothly through a standard piece of transparent Capricorn tube. This innovative design requires a specialized sensor, which I purchased from AliExpress for $1: https://www.aliexpress.com/item/32805007505.html Here's a step-by-step guide to assembling this optical replacement: Firstly, print the model (which doesn't require supports) and ensure it's properly aligned on your 3D printing bed. Then, using a 4.5mm drill bit, carefully drill through the entire hole from front to back in one smooth motion. Next, insert a single piece of Capricorn TL transparent PTFE tube into the housing, running from front to back. Avoid cutting the tube in two pieces, as it's semi-transparent and allows enough light for the sensor to function when there's no filament present. I removed the standard 3-pin header from the original sensor and soldered a new XHD 2.5 3P male header onto it. After that, simply insert the sensor into the printed housing. However, I encountered an issue with the pin configuration of the CR10S sensor cable and the new optical sensor. To resolve this, remove the pins from the end of the CR10S sensor cable and reinsert them in the correct sequence (as shown in a provided picture). Once you've completed these steps, you can connect the refactored CR10S sensor cable/connector to the new optical sensor. Your assembly is now complete!