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Micro DUAL/QUAD Extruder

by Gyrobot, published

Micro DUAL/QUAD Extruder by Gyrobot Apr 30, 2014

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Summary

Number 3 of 5 for Gyrobot's Extruder Week.

This is a dual extruder with a small footprint (105mm x 42mm x 42mm). Two can be placed back to back to create a quad (105mm x 84mm x 42mm). I got a friend to measure the size of a Replicator 2 single extruder (not dual) which is 71mm x 84mm x 76mm so it seems even the Quad has a smaller volume.

The fact that it is small, increases the possibilities to print with dual hotends where space or weight may be a factor. The pitch between the hotends is only 20mm for dual and quad.

I know Bowden extruders are one option where space is limited but I designed this with the requirement to print with FFX elastic filaments from Recreus, something that Bowden extruders can have issues with.

  • It can be mounted onto multiple types of carriages either in X or Y orientations.
  • Cooling of the hotends is provided from a single 40x 40 x 10 fan. Ducting built in through the extruder splits off some of the airflow and cools the Nema 17 motors, MK7 drive and the plastic body.
  • Two of these duals can be placed back to back to make a quad extruder for experimentalists pushing new frontiers. However, as far as I know, there is no turn-key solution for quad electronics yet, so this has not been tested. I don't know if it will keep cool sufficiently but feel free to make/test and report your findings.
  • Full filament support after the MK7 gear wheel allows a PTFE tube insert to be added down into the hotend for flexible filament printing. If you want to know how to print with this type of filament, please read the following article.
  • It is printable without support, however a small amount of support is modelled in to be easily snipped off afterwards.

Video of Filaflex printing at 90mm/s : http://youtu.be/qN4ZmwwCuR8
Here is a video of my first dual extrusion print : http://youtu.be/hbAAlZIslN0

Instructions

Print without support, but snip off the lower left foot that is by the cooling fan pocket.
A drilling template is provided that can be printed off either in plastic or on old school paper. The template is to show you what to do if you already have an extruder base mounting plate on your printer. I have an Orca 0.4x which is perfect for this template.
The idler tension springs are from Bulldog clips, one of the images shows these, choose a size that suits your requirements. They clip into small holes under the tensioner arms and also in the main body.
A 40mm thin PC fan is screwed to the extruder to cool the Recreus all metal hotends. My hotends have been extended by using a longer barrel. The hotends have a PTFE (3mm-OD / 2mm-ID) liner down inside them from the MK7 drive gear. This helps with flexible filament printing.
The extruder is kept in place by a single M4 screw but the M6 nuts on the top of the hot end (see photo) lock into the base of the extruder to stop it from turning.
You will also need 2 x 623 bearings for the idler arms.
I hope I have provided many pictures to show how all this fits together, so I wont waffle on much more, but feel free to comment if there is anything you need to know.

Orca Owners :
  • If you have an Orca 0.4x then you need to use countersink screws for the front X bearing holder. These screws need to be countersunk in the existing X plate so they sit under the extruder motor (one of the images shows this). You will need to upgrade the Gen 6 Deluxe electronics to something like RAMPS 1.4 which has dual extruder support.

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What type of stepper motor does this use nema 17 or 14.

Nema 17, of which you can get various thickness according to torque requirements.

Comments deleted.

Hey I just printed everything out and it all looks good. I'll post photos when I get it all set up. Only one question, where does filament guide go?

Hi, the filament guide should just press fit on top, this allows a PTFE filament feed tube to be held captive on my Orca. You may or may not require this part.

ah ha nice well I might go without I am currently making this for the Prusa I3 along with the carriage adapt by jbablo, thanks for the quick reply I will post photos of it all hooked up

This what I was looking for..... :-)

Is it possible to use another hotend? Like a Jhead, an Hexagon or a E3?

Carriage adapter to fit Gyrobot's Micro DUAL Extruder to Prusa i3, P3Steel (and similar)
by jbabio
J-Head version of Gyrobot's micro dual extruder

Awesome design! I have haven't printed them yet but I will definitely try the dual extruder :) Thank you for sharing.

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