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Jim's Flying Motor Mount Dual Extruder

by doctek, published

Jim's Flying Motor Mount Dual Extruder by doctek Nov 18, 2012
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Jim's Flying Motor Mount Dual Extruder by doctek is licensed under the GNU - GPL license.

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Jim's Flying Motor Mount Dual Extruder is a compact, light-weight, dual extruder which can be used on Mendel, Prusa, Wallace, and Printrbot 3D printers (and others) which currently use the single Greg's Wade's Extruder. This new design offers a true dual extrusion capability to these printers, allowing two color printing, or use of an alternate support material.


Print two each of jimsFMM45DualOK.stl, jimsFMM45DualLgGearOK.stl, and jimsFMM45DualSMGearOK.stl. The file jimsFMM45DualOK.stl contains the Extruder Body and the Tensioner. The “OK” means that the stls have been run through Netfabb and should slice cleanly. I used Slic3r and had no problems. After printing, you'll need to cut away the support material on the body. The file “gears with axis.stl” is for visualization of gear alignment in the scad file and is not meant to be printed.

The files jimsFMM45Dual.scad and jimsFMM45DualGears.scad are the design files. Commenting in the files will explain how to visualize the construction and print the pieces.

The files configuration.scad, metric.scad, and functions.scad are direct copies of the Josef Prusa files of the same names and are provided for convenience.

The file parametric_involute_gear_v5jkl.scad is a slightly modified version of Greg Frost's excellent parametric gear file. I want to fully acknowledge the great work of Greg Frost in creating this file. The gear designs in it made my extruder design possible. Many thanks, Greg! The few changes I've made are in the comments in the file. Place this file in a file folder named “inc”. Note that one of the changes I made causes the gears to render correctly even using “F5” in OpenSCAD. Be warned that this rendering takes minutes, not seconds!

Instructions for building Jim's Flying Motor Mount Dual Extruder are in an Instructable that I am releasing at the same time as I release this Thing. I'll edit this to add the link. Please refer to the Instructable for complete, step-by-step instructions, with lots of pictures.

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Stupid question: Can I print the parts in PLA?

Not stupid at all - thanks for your interest!

PLA should work just fine. The only potential problem is if your motors heat up. Then the mountings can soften and the motors can bend back so the gears don't mesh. As long as you put cooling fans on the motors (as recommended), you should be OK>

How hard would this be to convert to NEMA 17s? I run a K8200 printer, and weight isn't much of an issue. I don't have NEMA 14s readily available.

The OpenSCAD design files are download-able, so you are welcome to have a shot at a conversion to NEMA 17s. But be warned that the design took full advantage of the size of the NEMA 14s and would require a lot of rework to come up with the larger version. Probably the best approach would be to start fresh using my design for inspiration.

Please post your version when you do it! And sorry to sound discouraging, but it really would be a new design.

Already done! Have a look here: http://www.thingiverse.com/thing:515876

Jim's Flying Motor Mount Dual Extruder - body with no support
by doctek

Can you upload an STL file of the main body without the support structures? Some of them cause artifacts and lead to strange gap.


Instead of an adaptor plate for a vertical X carriage, how about punching 2 m3 holes through on 50mm or 80mm centers. I am trying to figure out how to do that - I think you would end up with one bolt through each extruder, and it could run into problems with levelling. It's a bit hard to pick off the distances from the scad file: how far apart do the outside holes for the two hot-end mounting screws end up?

I don't recall exactly. One quick way to get a pretty accurate measurement is to use the measurement tool in MeshLab. Then experiment with the SCAD files to find the value that moves the screws. This was one of my first major SCAD designs and isn't as well parameterized as it could be.

Do you have a mounting plate for a vertical x carriage?

Can you point me to such a plate for a Greg's Wade's? I might be able to modify that if it's a quick job.

Beyond that, I have provided my design files so others can modify them or adapt them to their own needs. Have at it and share your results.

Jim, the WHARP 3 was a vertical X carriage arrangement.

Indeed. But I don't think that carriage design fits directly on other printers - I'm not sure. That's why I asked for a pointer to a representative design.

What firmware are you using for dual extrude, I'm working on getting mine up and running now.

Have a look at Step 13 of the Instructable. All the details are there.

Thanks, that's brilliant. I apologize I didn't see the link before I asked.

witch printer did you use for the body? And can you make a mount for a printrbot wood extruder?

I used a modified Wallace design to print it, but any printer should work. Nothing special.

I'm not familiar with the wood extruder. Adapting the design to another extruder should not be difficult unless the new extruder body is a lot larger than the Ubis extruder. Then the spacing would have to change and a lot of details would need to be modified. But the design is open sourced, so go for it.

Can you upload a picture from the top?

Should have pictures and video very soon. I have a new X-carriage done and am mounting it on my Prussa.

Have a look here: http://www.thingiverse.com/thing:93513http://www.thingiverse.com/thi....
I'm getting steadily closer to actually extruding. Video soon, I hope!

X-Carriage for Jim's Flying Motor Mount Dual Extruder
by doctek

This is a really interesting design. I was really hoping to go dual direct drive but it is really hard to make it compact as you have done. Good work.. could we see some test prints with this if you have this installed already?

 Yes, keeping the design dual, compact and accessible - all at the same time - is not easy!

While I have extruded plastic with both extruders, I have not mounted it on a carriage so I can print with it. I need to design a new X carriage for my printer so I can do that. I hope to do that very soon.

It looks like the quickfit x carriage would be a great fit for this. You might want to take a look at it. I bet all you would have to do is print an adaptor plate for this extruder and you would be done. Keep us updated

Way to use bevel gears at funny angles! We need more of that on Thingiverse. Also, it looks like your main motor mount piece would print just fine vertically, without all that wacky support. Is there a reason you put it on its side?

 Glad you like the gearing. It was what made the extruder possible - I had to get the motors out of the way of the filament, the tensioners, and each other.

The motors started out at a 30 degree angle which was too shallow to print vertically. Also, the printing technology I had available was having trouble even at 45 degrees (it's since matured remarkably), hence the support material. But your suggestion is a good one, and timely. I will try printing vertically next time I print this.

Is this really claimable as "lightweight" with 2 nema 17s on it?

 Those are NEMA 14s, not 17s.

How much torque are your 14's? I was looking at adapting the wade extruder pattern to nema 14, but the specs out there state that 40 newton-cm of holding torque is needed, any my pair of NEMA 14s from an earlier project are 6.5 newton-cm torque. I was wondering what level of torque you have been successful with?

I don't know the torque spec. Usually, I get an idea of the torque by measuring the resistance of one coil. My best NEMA 17s measure about 1 Ohm. My NEMA 14s which I am using measure about 3 Ohms. I have some other NEMA 14s that measure 6 Ohms and don't work in this application. Note the need for cooling fans to dissipate the heat when the motors are running. Turning the current down so heat is not a problem results in the motors not putting out enough torque.