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PG35L Micro Extruder V4 - For J-Head

by UltiBots, published

PG35L Micro Extruder V4 - For J-Head by UltiBots Dec 24, 2012

Description

Version 4 is designed for short shaft PG35L-048 motors (8mm). This version has integrated bearing to appose idler tension. Use of the external bearing is no longer needed. Also, this body has a snap-in slot for a J-Head hot end which eliminates the aluminum slot plate. The snap-in idea was derived from scottmayson. This Micro Extruder has been tested on MendelMax and Prusa.

Go to www.ultibots.com for Hobbed Drive Gears and Bearings. MendelMax 1.5+ kits and printed parts are available for purchase.

Alibre PE source files included.

Recent Comments

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Blue_Alien -

Check out thingiverse.com/thing:42112. It is still untested but should provide better shaft support.

Brad
Blue_Alien -

I would recommend pulling the motor from the body, turn down the pot counter clockwise, then make incremental micro turns clockwise, pinch the hobbed drive gear, then run the stepper 10mm at 100mm/sec in Pronterface. Keep making the micro adjustments until holding the drive gear becomes difficult. I have found too much amperage to the stepper is problematic.

Regarding motor shaft wobble, our production printers have been running almost daily for months without issue. Our retract is set to 15mm/sec and we are using RAMPS 1.4 with A4988 stepper motor driver using 24 volts input.

Thanks for trying our design. I hope this helps - Brad
I can't get this to push filament very well. It is skipping steps even with the pot turned up on the driver. The motor shaft has too much wobble without the external shaft support.

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Instructions

Hardware required: M3x40 bolts and M3 jam nuts for the idler (x2) M3x25 bolts and M3 jam nuts for the motor mount (x2) 605ZZ bearings for internal and idler (x2) M5x20 bolts and M5 jam nuts for the bearings (x2) M5 washers (x4) M4-10 bolts and M4 jam nuts to secure to x-carriage (x2)

You will need to remove and drill out the support layers on the idler and body.

Try our gear puller: http://www.thingiverse.com/thing:31660

This extruder works well with AlephObjects Supa-Flat X-Carriage thingiverse.com/thing:10646 The bearing holders shown are: thingiverse.com/thing:15205, the last one on the download list. SDP_bearing_mount_for_y_axis__on_side_with_square_ends_and_fixed_holes_by_Simon.stl file.

01/10/13 - Added brimmless STL. Also has better internal breakaway supports.

I can't get this to push filament very well. It is skipping steps even with the pot turned up on the driver. The motor shaft has too much wobble without the external shaft support.
Blue_Alien -

Check out thingiverse.com/thing:42112. It is still untested but should provide better shaft support.

Brad
PG35L Micro Extruder V5 - For J-Head
Blue_Alien -

I would recommend pulling the motor from the body, turn down the pot counter clockwise, then make incremental micro turns clockwise, pinch the hobbed drive gear, then run the stepper 10mm at 100mm/sec in Pronterface. Keep making the micro adjustments until holding the drive gear becomes difficult. I have found too much amperage to the stepper is problematic.

Regarding motor shaft wobble, our production printers have been running almost daily for months without issue. Our retract is set to 15mm/sec and we are using RAMPS 1.4 with A4988 stepper motor driver using 24 volts input.

Thanks for trying our design. I hope this helps - Brad
Could you provide a version of the STLs without the built-in brim ?

For pulling the aluminum gear, I simply sawed it off with a metal saw (and made a useful flat on the shaft without realising it).
Good Idea in sawing. Nice that it also provided a flat on the shaft.
I will upload a brimless STL shortly.
Brad
is there anyway to convert the source files to openSCAD by chance? If not how about converting the bearing size to 623zz or 605zz? I would be more than happy to do the work, but dont have Ailbre.

thanks,
matt
Matt -
Alibre PE doesn't export, so sorry on openSCAD.
BUT... Alibre PE, I believe is on sale tomorrow for $99.
Right now I am not able to tweek designs.
Sorry - Brad
Brad, I've given up on trying to fit the extruder above the print platform on the standard Rostock, just not enough room. I tried modifying your PRT file, but my skill at Alibre PE is quite lacking. Anyway, what I'd like to do is modify this design to mount below the platform. What would have to be done is to trim out the bottom so that it looks like the top, with curved ends to minimize weight and interferences. The top, which would attach to the print platform, would be squared off to attach to the 4mm bolt holes on the platform. These would be 43mm apart, centered on the filament feed hole, with inserts for mounting 4mm nuts.

If you want to pursue this, I think you might have another product which you could offer.

Be happy to go over this in detail.

Thanks so much,
John
John -
Currently jammed up with ultibots.com. I want to sell a Rostock in the future. I will look in to this mod then.
Sorry I can't help with this now.
Brad
Brad, No worries. I'll just hack some mod plates to mount on top of your excellent design. Acetone and ABS can do wonderful things...
For this eminebea motor, could someone help me with its wiring... Maybe im just a newbie, but I certainly dont want to burn it or my driver up! Thanks in advance!
tonyhill -

Assuming you have the green 4 pin connector...

You should be able to plug that directly to ramps for testing. You might have to reverse the connector 180 degrees to get extrude/reverse going correctly.

I found pairs yellow/orange & brown/black work on my PG35L motors - YMMV.

Hope this helps - Brad
Oh, and I just used my garage gear puller on the fixed gear on the motor. Easy-peasy. harborfreight.com/14-piece-gear-puller-set-30305.html
jpickens -

Thanks for the link... that will surely pull it!
Brad
Already printed one, and promptly started hacking away at it to fit within the confines of my Delta Rostock print platform. Looks like the motor hitting the delta arms will constrain the motion of the printer somewhat, but still will be something like 220mm by 180mm build area.

Thanks for the design, really like the built in supports for printing. Got a little sloppy for the idler bearing support, but it will be fine with the washers and 4mm bolt in there.

Do you suppose I'll need to do something to the feed holes to use 1.75mm filament with this?
jpickens -
I will tweek the design for 1.75 filament and upload by the New Year. Going to work today and traveling for 4 days.
Thanks for trying my design.
Merry Christmas,
Brad
Getting those gears off is certainly quite the adventure. I bought 20 of the PG35L's with the gear attached. I tried all kinds of printed solutions, various Dremel cutting wheels and just plain cursing at the damn things. In the end I wound up using this tool and lube to get them off.

amazon.com/gp/product/B000FH89HO/ref=oh_details_o00_s00_i00

amazon.com/Gun-Oil-Gel-2-Oz-Package/dp/B005K2OSOW/ref=sr_1_1?ie=UTF8&;qid=1356411238&sr=8-1&keywords=gun+oil+lube

The lube goes on the threads for the faucet puller and makes a huge difference in getting the gears off! I also put a drop on the tip of the PG35L shaft as well to help protect the tool and motor from excess friction.

Thank you so much for the modified short shaft design. I thought I was going to wind up using these motors as paper weights forever!
scotty1024 -

Thanks for trying my design and for the links, etc...
Merry Christmas,
Brad
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