garethky / Slice-Mosquito-Direct-Tool-Head

Models and Instructions for making a Mosquito/Bondtech direct drive toolhead for the E3D Tool Changer platform

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Tolerances for filament path should be widened a bit.

im000000 opened this issue · comments

I was having some difficulty getting my filament to feed through the opening into the hotend. I think the filament path should be widened a bit to allow for easy passage of filaments.

I'm always looking for data to support changes like this. I have been benchmarking this design against the Prusa MK3S parts because they have so many users successfully printing and using them. I guess I never checked this particular dimension:

The filament path in the current design is set at 2.0mm. It's also has a "birds mouth" profile to combat any blockage due to bridging:
Screen Shot 2021-02-04 at 12 40 06 PM

The Prusa design uses a value of 2.4mm for the filament path diameter:
Screen Shot 2021-02-04 at 12 48 30 PM
see: extruder-body.stl

So a bit is ~0.4mm 😁, this change will be in the next commit to the dev branch. I also added the same 0.6mm filet they have around the opening. The Prusa part don't have the "birds mouth" because the split line is down the middle of the filament path, meaning there is never a bridge. The birds mouth does give slightly more room for the filament to wriggle side-to-side vs a straight tube. I'm going to remove it from the bottom, since its technically unnecessary there. If we find there is a problem with flexibles we might try removing it from the top as well.

Screen Shot 2021-02-04 at 1 09 26 PM

I'll put these changes into the dev branch when I make the next update.

Just to be very clear: I haven't pushed this change to the development branch yet! I have a bunch of changes that I am doing in the OnShape file right now:

  • Soft mounting the 5015 fan
  • Totally re-designed part cooling nozzle (this is my third attempt)
  • Fixes to the fan shroud to prevent warping
    I need to print these changes myself and validate that the tool at least passes the heater tuning test before uploading them. If all goes well I should have something to post by Monday.

And maybe I should open all 3 of those issues as bugs here to track whats being changed...

I just pushed this change to development along with all the other work.

The dev branch and mainline parts are not compatible. The idler had to be shortened to make room for the 40mm fan. If you are trying to mix parts that might cause an issue.

I don't understand issue #1? Are you saying that you can't get the idler closed enough? The idler gears mesh before the face of the idler makes contact with the extruder body. The actual design has the filament squished slightly with the idler still not touching the face of the extruder body:

Screen Shot 2021-02-08 at 10 24 22 PM

For #2, this design is pretty standard now. Just looking around, both the newest version of the Prusa MK3S extruder and the Voron Afterburner extruder use this same concept. Printing the complex geometry is more reliable and provides tighter tolerances than cutting the PTFE without a jig did.

It is possible to configure parts in OnShape to have optional features, so I could have 2 versions of the extruder block, one with the feature and one with a plain hole, if you really want to cut the PTFE to shape.

In the above linked Prusa issue they note that the "ideal" designed gap between the bondtech gears is 8.7mm. I based the gap in this design on measurements taken from a BMG extruder. I got 8.6mm. The filament path is straight relative to that spacing:
Screen Shot 2021-02-11 at 4 32 33 PM

I'm going to call that "good enough".

This is an interference projection with +2 degrees of closure on the idler beyond what is possible now. I'll see what I can do to make this work for tighter grip on flexibles.
Screen Shot 2021-02-11 at 4 44 06 PM

Here you go: Add 2 degrees of clearance to idler

I don't actually think this is going to do anything for your issue though. But you can try it with the drive gear not in place and see that it closes more. Its just that the gears are fully meshed and can't close anymore. The cylinders of the Bondtech gears never touch at maximum closure (if they did we would have problems hitting the set screw!).

I tried hand feeding some TPU through an extruder (turning the reduction gear by hand so I could feel what was going on) and I didn't have a problem. You can apply a LOT of tension with this design. Its because of the leaver arm design and short spring, see issue 6

I don't see any pictures, can you try posting again? i think you are responding in email and that doesn't work on github.

Please only reply directly on github, email does not post images.

Here is my take on this:

This is the modified dev branch idler installed without the drive/reduction gear. As you can see it closes until the barrel of the idler gear makes contact with the circular section of plastic that the filament feeds through.

IMG_6022

This is the same setup, shot so we can see how closed the idler gets. Note the small gap between the idler and the extruder body:
IMG_6023

So from the above there cant be any plastic in the way between the idler and the extruder....

This is with the drive/reduction shaft installed. I cut a hole in the back plate so we can see a little better here. Its important that the back bearing is used to check this because otherwise you will skew the shaft and the two gears won't be parallel. As you can see, the idler is not nearly as closed as it was above. The gap between the idler body and the extruder is larger. This is because the gears have fully meshed. A Bondtech gear set cant get any more closed than this.
IMG_6024

This goes for the original idler arm as well, its no different, there was just less of a gap to the extruder body by design. And the idler does not touch the hub on the reduction gear. If it did the shaft would be the thing touching and that's not possible because Bondtech designed the gear set and the hub to have more clearance than that.

Closing as the original request for a wider filament path has been implemented and the other issue is now moved to #7.

On the Duet 3 you can pick the voltage for both the two fan independently.

On the Duet 2 you have to pick between 12V and 24V for all fans. There are 12V 5015 fans available so you can run the Noctua. You can also get 24V 40mm fans if you want to stick with 24V, it just wont be a Noctua.