New extruder carriage design for E3D Bowden Hot end V5

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satoer
Posts: 436
Joined: Mon Oct 01, 2012 8:00 pm
Location: Netherlands

New extruder carriage design for E3D Bowden Hot end V5

Post by satoer »

I’ve designed a whole new carriage to make the Felix 1.5+ 3D printer compatible with the e3D hot end. V5 Bowden tube version
_DSC5776-edit.jpg
Although I’ve made great prints with the original hot-end, I’ve had some problems with it. The main problem I’ve had is jamming of the filament between the PEEK and the upper aluminium part. Even though the parts where firmly fit. I couldn’t use more than 0,75mm retraction which resulted in oozing over the printed part.

Pro’s for the e3D Bowden tube hot end and carriage:
  • - Way lighter X carriage because of the removal of the extruder stepper motor
    - All metal design, no more PEEK
    - Better cooling
    - Can reach Higher temperature. (don’t know why, but I can reach 270 degrees easily. The old one couldn’t reach 240 stable).
    - Way faster on temperature
    - More nozzle hole diameters available
Con’s:
  • - More expensive
    - You can't use flexible rubber-like filament trough a Bowden tube
You can buy this hot-end on: http://e3d-online.com/
I'ts specifically design for the V5 version, The v4 or if a newer version comes up with a new layout cool-ribs, it will not fit. The cool ribs are printed inside the PLA clamp.
It does not use the supplied 30mm fan. Instead it uses the original 40mm Felix fan. More cooling less noise. I use it on 12V. But I think 5V works fine also.

It’s a two part design. The extruder carriage and the Bowden feeder.

This is the filament tension releasable feeder. Discussion over here:
_DSC5764-edit.jpg
The extruder carriage is made in a way that the nozzle-end is on the exact same location as the original hot-end.
exploded view.jpg
I’ve made it also very ease to remove the complete hot-end. Just loosen two bolds and turn the door open.
_DSC5779-edit.jpg
_DSC5778-edit.jpg

I’ve made a new design for the extruded filament cooler, it’s more circular around the nozzle tip. So the part isn’t cooled from just one side.

Here is a video of the extruder in progress:
http://youtu.be/ZsNm0UfQsyQ

Everything is downloadable on thingiverse over here:
http://www.thingiverse.com/thing:159142

You have to edit the thermistor settings in the firmware:
open up the firmware in Arduino. Select the Configuration.h tab
Change:

Code: Select all

#define TEMP_SENSOR_0 8
to:

Code: Select all

#define TEMP_SENSOR_0 1
If you want to use ABS, you may want to upgrade the max heat:

Code: Select all

#define HEATER_0_MAXTEMP 275
(I use ABS on 270 degrees, PLA on 215 degrees)
Last edited by satoer on Wed Oct 01, 2014 9:07 pm, edited 14 times in total.
My Felix 1.5 printed designs on Thingiverse
E3D V6 Hot end upgrade for your Felix
Tweezer bracket for your Felix
Led bar upgrade for your Felix

Makron
Posts: 110
Joined: Wed Mar 20, 2013 1:29 pm

Post by Makron »

This looks very NICE !

Going to try it out.

Danny-Lelystad
Posts: 19
Joined: Sun Mar 17, 2013 11:20 am
Location: Netherlands

Post by Danny-Lelystad »

Looks great Satoer, i will try the bowden feeder in my Felix 2.0 with 'original' Felix hotend somewhere in the next couple of weeks. I already use a bowden cable to guide filament, its a pneumatic tube with inner diameter 2.0 mm

satoer
Posts: 436
Joined: Mon Oct 01, 2012 8:00 pm
Location: Netherlands

Post by satoer »

Thanks.

I've updated the first post with firmware changes. The e3D comes with a different thermistor which needs a different calibration table. The original firmware had a 10 degrees offset with this thermistor.
My Felix 1.5 printed designs on Thingiverse
E3D V6 Hot end upgrade for your Felix
Tweezer bracket for your Felix
Led bar upgrade for your Felix

Makron
Posts: 110
Joined: Wed Mar 20, 2013 1:29 pm

Post by Makron »

Ordered the Hot end yesterday, and printed out youre parts.

Is there any word for the basr part? Else ill just have to draw it myself.

satoer
Posts: 436
Joined: Mon Oct 01, 2012 8:00 pm
Location: Netherlands

Post by satoer »

No not yet, the message is still floating in the outbox, so he hasn't read it either. If he hasn't responded this weekend, ill give him a call. Don't worry, I can always adjust the Superhornet's version if I can't get in touch with him or if he declines.
My Felix 1.5 printed designs on Thingiverse
E3D V6 Hot end upgrade for your Felix
Tweezer bracket for your Felix
Led bar upgrade for your Felix

alanh
Posts: 78
Joined: Tue Jul 23, 2013 7:08 pm

Post by alanh »

That's the piece I'm waiting on now before I dismantle :-)

Awesome work indeed satoer !!

Have you thought about dual extruder using this system ?

Mayhem
Posts: 169
Joined: Tue Jan 08, 2013 4:15 pm
Location: Finland

Post by Mayhem »

Ill try this once you have all the files :) whit this desing maybe i get little less vibrations.
Felix 2.0----> 3.0
V4 hot end
Simplyfy 3D
Kisslicer
Autodesk fusion 360

satoer
Posts: 436
Joined: Mon Oct 01, 2012 8:00 pm
Location: Netherlands

Post by satoer »

Still haven't received permission yet. Even called, but got voicemail.

Now I've reworked Super hornet's rail base. You can download it in the first post. The first who prints it, please let us know if it's okay, I haven't printed and tried it.
My Felix 1.5 printed designs on Thingiverse
E3D V6 Hot end upgrade for your Felix
Tweezer bracket for your Felix
Led bar upgrade for your Felix

Makron
Posts: 110
Joined: Wed Mar 20, 2013 1:29 pm

Post by Makron »

making it atm thank you.

I cant test it yes my hot end has not arrived yet , and im waiting on my 2.0 upgrade set :D

Will let you know when its here.

p.s sorry you all have to turn youre screen 90 degr. :lol:
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