Hey! This thing is still a Work in Progress.
Files, instructions, and other stuff might change!
MK5 / MK6 Thermal Barrier Heatsoak / Cooling Mod
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Published on January 1, 2012
Description
[Edit] This failed on me. The holes are too big and the PTFE expanded into the holes under filament pressure. Now I can't extract the filament or the tube. I'm still confident it would still work but with lots of much smaller holes. Next I may just stack TO-5 heatsinks on the tube. A buck each on ePray. [/EDIT]
This thing is a modified MK5 / MK6 thermal barrier. The hole arrangement significantly reduces heat conduction / heat soak up the thermal barrier tube.
This arrangement of staggered holes retains structural integrity that is otherwise lost with the horizontal cut-slit method.
This solves or greatly reduces the problem of heat soak during long prints causing filament to soften and / or jam/expand in the PTFE.
The thermal barrier dxf file is Makerbot's not mine.
This thing is a modified MK5 / MK6 thermal barrier. The hole arrangement significantly reduces heat conduction / heat soak up the thermal barrier tube.
This arrangement of staggered holes retains structural integrity that is otherwise lost with the horizontal cut-slit method.
This solves or greatly reduces the problem of heat soak during long prints causing filament to soften and / or jam/expand in the PTFE.
The thermal barrier dxf file is Makerbot's not mine.
Instructions
Use a fine Sharpie and make radial marks on your tube just above the insulation and kapton tape. Make another mark just below the flat barrier plate.
Now make axial marks quartering the tube. Alignment isn't super critical but keeping close will help it look nice and get four holes with a fairly consistent web remaining.
Clamp it horizontally in a vise. Also plan your cuts to cut towards the end, when those four are done, shift out and cut the next four, thus leaving the somewhat weakened piece not bearing any cutting load.
I used a 3/16 end mill to plunge cut each hole. Rotate and cut the remaining 3 on that radius. Shift the thermal barrier tube out of the vise, clamp, index, and repeat.
If you're doing this on a drill press rather than a mill you can use a rat tail file to file a flat spot to help prevent drill bit drifting when starting.
When one use the back of a No 11 Xacto blade or your favorite deburring tool to debur the inside edge of the holes.
Re-assemble your hot end and enjoy minimal heat soak above the thermal core.
Now make axial marks quartering the tube. Alignment isn't super critical but keeping close will help it look nice and get four holes with a fairly consistent web remaining.
Clamp it horizontally in a vise. Also plan your cuts to cut towards the end, when those four are done, shift out and cut the next four, thus leaving the somewhat weakened piece not bearing any cutting load.
I used a 3/16 end mill to plunge cut each hole. Rotate and cut the remaining 3 on that radius. Shift the thermal barrier tube out of the vise, clamp, index, and repeat.
If you're doing this on a drill press rather than a mill you can use a rat tail file to file a flat spot to help prevent drill bit drifting when starting.
When one use the back of a No 11 Xacto blade or your favorite deburring tool to debur the inside edge of the holes.
Re-assemble your hot end and enjoy minimal heat soak above the thermal core.
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MarcusWolschon
on
January 3, 2012
said:
I solved this with 2 fans and some heat-sinks.
Less risk involved.
FreeRider
on
January 2, 2012
said:
Interesting...I've never had a problem with ABS but I do notice on prints longer then ~2hr with PLA I get enough heat soak (despite my cooling fan) to jam the extruder. I may have to try this approach.
License
MK5 / MK6 Thermal Barrier Heatsoak / Cooling Mod by nauglanch is licensed under the Attribution - Share Alike - Creative Commons license.
More from nauglanch
THANK YOU!! 8-)
What a great idea
Just made this mod after fighting 2 weeks to just make a decent print with PLA on my MK6.
Before I was not able to finish a 15 min print before jam, now I have just finished a 60 min print :-D
NOTE: I only drilled one row of 5 mm holes, not 2.