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Extruder carriage design for E3D Bowden Hot end V6

Posted: Wed Oct 01, 2014 9:21 pm
by satoer
After lots of requests, I’ve updated the E3D V5 hot end carriage to the E3D V6 Hot end bowden tube version.
DSC08470-low.jpg
Left V5 version. Right V6 version.

The hot end clamp is completely redesigned, but the baseplate and fan duct are the same. So if you upgrade from the V5, you only have to print the “cooler base” and “cooler door”
This hot-end carriage makes the bowden tube E3D hot-end V6 ( http://e3d-online.com/ ) compatible with the Felix 3D printer (1.5 and up).
DSC08471-low.jpg
DSC08473-low.jpg
DSC08476-low.jpg
Although I’ve made great prints with the original Felix 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
    - No clogging and jaming anymore!
    - Cheaper

Con’s:
  • - 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 V6 version, The v5 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:
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The extruder carriage is made in a way that the nozzle-end is on the exact same location as the original hot-end.
exploded-viewV6-low.jpg
I’ve made it also very easy to remove the complete hot-end. Just loosen two bolds and turn the door open.
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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 (V5) extruder in progress:
http://youtu.be/ZsNm0UfQsyQ

Everything is downloadable on thingiverse over here:
http://www.thingiverse.com/thing:484581

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)

Special thanks to Guillaume from Felix printers to supply the rail-base.

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Thu Oct 09, 2014 1:26 am
by maggs
Many thanks Satoer. You're a legend.

I've printed the V6 version and it works a treat. I'm also using your quick release extruder and that works well too. My Felix 1.5 is now usable again and no jamming. There is way less vibration on the table with the bowden setup due to less moving mass on the X axis. My prints are great.

Steve

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Thu Oct 16, 2014 4:07 pm
by osta2
After a few melted PEEKS, I moved to E3D V6 too a while ago and made my own (pretty ugly one) carriage for it but will definitely try to use yours since mine don't have a filament fan). Well done, thank you!

What cold end do you use? I'm using Wades geared cold-end and the extrusion consistency is not always perfect.

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Sun Oct 19, 2014 12:47 am
by kerog
Is there a dual-head version?

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Mon Oct 20, 2014 12:05 pm
by satoer
@Osta2: Cold end? You mean the feeder? I've designed my own:
http://www.felixprinters.com/forum/view ... ?f=9&t=619
Image

Sorry, I haven't designed a dual head.

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Sat Nov 15, 2014 10:01 am
by Peach3D
Looks really good man, after reading this I couldn't resist ordering one which I did yesterday! Looking forward to receive it monday! But before that all I have some questions. Last night I started printing the parts to have everything ready when the hot-end comes in. I use Simplify3D but last few days it makes a complete mess off the ''bigger prints''! Small thing are fine, but I also keep finding it very hard to control the first layer. Which software do you guys use? PS. I use original Felix PLA.

All advise is very very welcome!

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Mon Nov 17, 2014 9:15 am
by satoer
Thanks.
I don't think it’s a problem of the slicer. Make sure the bed is calibrated exactly flat. And I use these Avery sheets:
http://forum.felixprinters.com/viewtopi ... very#p1915
Finally I adjust the Z rod while printing the first layer (pressing it trought the steps) to calibrate the distance between hot-end and bed perfectly.

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Sat Dec 06, 2014 6:40 pm
by DBL
Hello all,

thanks to this very nice design of satoer, I just finished installing the E3D Bowden Hot end V6 on my Felix 3.0 dual. Actually I decided to downgrade my dual to a single extruder. I think that a weakness of the dual Felix is the holding of the extruders. Always difficult to set the relative height of extruders ...

So for now I switched to a single extruder (I will maybe come back to dual in the future). Now I wanted a robust and performant extruder with the possibility to change the nozzle diameter from fine to coarse.

Satoer design is very good and fit perfectly.
Two remarks :
- for the gear of the extruder motor , which push the filament, I had to move it on the motor shaft a few millimeters away from the motor so that the feeder works correctly.
- in the firmware, the thermistor setting must be change from "TEMP_SENSOR_0 1" to "TEMP_SENSOR_0 8", it is the opposite of what Satoer says in the first post. Probably a mistake.

Now it is time for more testing. I am very happy that the weight of moving mass on X-axis is drastically reduced.

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Wed Jan 14, 2015 5:45 am
by kerog
Satoer, have you printed the Make Shootout objects?

http://www.thingiverse.com/thing:533472

I'm curious to see if your design does better with bridging than the standard version.

Re: Extruder carriage design for E3D Bowden Hot end V6

Posted: Fri Jan 16, 2015 10:11 am
by satoer
Nope, haven’t tried these objects. Although I personally think this is more an slicer test than a extruder test. A simple change in the slicer setting can make such a difference with overhangs and bridging.