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E3D i3ext dual hybrid extruder

by jkoljo, published

E3D i3ext dual hybrid extruder by jkoljo Jan 16, 2014
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Summary

  • This design is a derivative of my previous i3ext release, originally made by sgraber. It uses the same E3D compatible mounting rail, and adds an option to use a bowden fed second extruder.
  • The innovative part of this extuder is that it feeds the first extruder via a gear system, and the second with bowden. That allows very accurate prints using the first nozzle, and semiaccurate prints using the second nozzle, making it perfect for printing support material, and even a second color with a well tuned bowden system. It is a great tradeoff between carriage weight and accuracy.
  • The bowden part of the system is compatible with 1/8" standard pneufit, and 4 mm OD bowden tube. The hot ends will be 25 mm apart, a minimum distance for E3D hot end. There are two fan shrouds available, a thin version is needed if your X carriage comes in the way.
  • I have been testing the system for a few months now, and it works great! Here is a print made with the bowden fed extruder. http://www.youtube.com/watch?v=Ef02mAOPs5s
  • The v3 extruder has reinforced back body, cleaner fan mount holes and a place for a short PTFE tube for direct extrusion side, making it much better for super flexible filaments!
  • The bowden extruder I am using:
    http://www.thingiverse.com/thing:26817
  • Original i3ext by sgraber:
    https://github.com/sgraber/i3ext

Instructions

  • Assemble direct drive section using the instructions in my previous i3ext mod (see sources)
  • Cut some bowden tube, and insert into the 4 mm hole under pneufit
  • Install pneufit
  • Install hot ends and fan shroud
  • To calibrate the nozzle heights, place pieces of paper behind the upper or lower linear bearings in the carriage

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I considered doing a single fan cooling for dual E3D's and was talked out of it. How have you found it works? Rumor was that it would cause PLA to jam in the heatbreak.

Can you take a temperature measurement on the heatsink?

The heatsinks are relatively cool while printing. I have since moved to liquid cooling, so I cannot make any measurements. I did not encounter any jams.

would any modding be required for a v6?

The upper geometry of v6 is identical to v5, so no modding is required.

Very nice design. I'm almost certainly going to use this for my Prusa i3. Just one question—What diameter of filament does it use? I have a bowden extruder that can use 3mm filament (which I use), but there does not seem to be much info on the geared, direct extruder. Can it use 3mm filament? Also, is the extruder compatable with bowden-fed 3mm filament?
Thanks!

It is intended for 1,75 mm filament, sorry, 3 mm is not compatible at the moment.

It seems that the OpenSCAD file has a variable for 3mm filament, and appears to make it comparable. Would that work, or are there other underlying problems with 3mm filament?

Yeah, it will work. You also have to modify PTFE tube diameter if you intend to use the dual extrusion feature.

Dude. That's was exactly what I was looking for! I was planning to design myself but I will totally check your design first! Thanks for sharing!

What i am about to get my own i3 and have been looking for both direct and bowden on same dual extruder and this is it. came up with the thought of using direct for filaflex and bowden for PLA or ABS. looks like you have your bowden tuned in pretty well i hope to have the same success. i'm still an uber noob in this but looks great.

dual extruder with video showing only one material being used?

Yeah, well, what can I say. I already made the vase video for another purpose, and I am too lazy to make another one :)

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