Dualstrustion nozzle leveling Fixture
by einer_designs, published
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Your jig saved me a lot of grief. The process is a PITA, but without your jig, it would have been virtually impossible. Thanks!
Theoreticallly yeah, howeverI have found that when dealing with mass manufacturing and precise alignment must be made (especially with threaded part heights) it is best to have some way to adjust for manufacturing tolerances. If you do not build this into the design and plan on perfect manufacturering you with have issues (and high expences)
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The main issue stems from the fact that the extruder bar is threaded where it accepts the nozzle(part #MP2590 if you have downloaded replicator part files). As well as having a nut at the top and bottom of the nozzle...This many threaded parts makes getting the level and orentation right next to impossible....I beleive that the top and bottom nuts will work as jam nuts and fix the extruder nozzle in place, if tightened properly, making the threaded bar redundant.
To fix this I machined a new mounting bar (MP 2590) with the holes NOT threaded (I used a 6 mm hole this left a little slop you might try smaller to get better alignment). You may just drill out you existing mounting bar (careful a replacment might be hard to get), I wanted to presserve mine in case I had to go back for some reason.
I still needed a reference to level the nozzles on my new mounting bar. I designed this simple fixture that allowed me to get them within .001 inch.
You simply adjust the top and bottom nuts until you get the nozzles level (use feeler guages to measure the gap between the nozzle and fixture). Make sure you really tighten the nuts against each other such that they do not losen.
You will have to recalibrate the nozzles offset. The calibration routine on your replicator should allow for this.
The only risk I see with this change is that the nuts ?may? loosen over many heat cycles, if the nuts are tightened enough this should not happen. So far I have not had a problem with this.
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