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AJGW Alain-Jonas-Greg-Wade's Extruder

by AlainMouette, published

AJGW Alain-Jonas-Greg-Wade's Extruder by AlainMouette Jan 27, 2013

Description

A few things annoyed me when I built a new Extruder, so this project started to be just a few fixes but then I ended up fixing a lot of small issues.

This is just one more in a long line of extruders derived one from the other. I named it AJGW to reflect contributors in the main line, but I did add all interesting accessories like the heringbone gears and fast release lever.

Here are some of the new features:

) new concept split filament guide, fixes better and allows easier access. ) Idler hinge doesn't touch the gear anymore. ) option (default) to use 5/32" screw for the idler which is easy to find ) longer oblong hole for the motor screws. This eliminates the need to remove the motor when testing or adjusting the heringbone gears. ) Top access to screws with ball end allen wrench. This allows for much easier attaching and removing, specially when there is a fan duct. Optional without nut fitting in base. ) Heringbone gears a little thiner and nicer looking. Better fit of the screw ) Open access to the insides for cleaning and inspection, just like Greg's ) Redesigned Fast Release Lever but keeping the same concept ) reinforcement to the upper idler screw attaching point, this was a frequent point of breakage ) reinforcement behind the tractor screw's bearing, to avoid frequent breakage ) reinforcement on the top with a little extra height ) Idler printing sideways, this avoids weakness in the hinge screw ) thicker motor mounting base so that M3x10 screws can be used without extra spacers ) Various external support structures, prints better without automatic support and it is easy to clean. ) Parametric, various simplified optins including 1.75 filament ) Many small things that you will not even notice that they aren't there anymore to annoy you...

All metric screws, except for the long idler screws that are not available as metric.

A few extras are included, like washers that you can print instead of going out to buy them.

It was originaly thought to be used for 0.25mm layers, but it has been tested by some friends with 0.4mm too.

I am releasing a few options that make sense to me and to some friends. If you need a different option and are having trouble with the .scad files, please post a comment and I will be glad to include other options.

2013/feb/17: there is an adapter for the Prusa i3 here http://www.thingiverse.com/thing:29795 please let me know if it works!

2013/mar/17: I found another nice support here: http://www.thingiverse.com/thing:57668

Version 1.1: small reinforcement in the Idler, included STL files for both 4mm and 3/32" (very usefull only in Brazil)

Recent Comments

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May I ask what variations I'll have to make to obtain a version for 1.75 mm filament?
It was not mentioned in the instructions and I only have 1.75 mm filaments
Anyone looking for the clothespins listed, here's an Amazon link: amzn.com/B000HJDCWW
Hi,

I like your Version of this Extruder. But is there a version for 1.75mm filament?
I´m not able to change it by my self.

Thanks

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Instructions

This thing needs a well calibrated 3D printer, but not a high precision one. Please see Slicer parameter at the end of these instructions. Be carefull not to use Brim for the big gear and washers. Some parts have optimizations for layer height/width, please check the files names carefully

After printing all parts, clean the brim and all support material.

=== List of printed parts:

1 Extruder body 1 Idler 1 big gear 1 small gear n M8 washers, stl for 1.2 and 2 mm are included 2 4mm (5/32") washer, to be inserted between the screw and the spring.

=== BOM, vitamins needed:

3pc 608 bearing 1pc 8mm axis for the idler, length=19mm (or 5/16") 1pc M8 tractor screw 2pc M8 nuts 3pc M3x10 screw for the motor 1pc M3x8 set screw for small gear 1pc M3 nut 3pc M3 washer 2pc screw 5/32 x 2 1/2" this is 62mm long (or optional: M4x60) 2pc nut 5/32" (or optional: 4mm) 2pc M4x 25 hex screw for fixing the base, YMMV 2pc M4 nuts 4pc M4 washers 2ps cloth peg springs, these are cheap and just perfect for the idler 1pc Nema 17 stepper...

=== Adjustements:

The most important adjustmaent is the aligment of the heringbone gears or they will wear out very fast. The EXTERNAL SURFACE of both gears have to be even for correct operations, beware that the small gear is bigger on the inside to allow for some printing variations.

The motor should be fixed so that there is no slash but WITHOUT PRESSING the gears toghether. Adjust with filament inserted and springs tensioned fo avoid surprises.

======================================================= ==== Recomended Slic3r settings ====

from Slic3r 0.9.7 up there are no (big) fill problems But this has generaly been optimized for these parameters Print Idler first to see if all goes well Allways use RepetierHost to check if Gcode is ok !!!

File extensions: .stl no optimization for layer height/width .25.stl for printing with 0.25 layer height .40.stl for printing with 0.40 layer height .2550.stl .25 layer height, but width must be 0.50 (see bellow) .4060.stl .40 layer height, but width must be 0.60 (see bellow) .scad files is not dependant on layers height gears should allways be 0.25 height, but can be 0.4 on a good printer NOTE: all parts have their own built-in support (except one idler file)

Print settings > Layers and perimeters
    Perimeter (minimum)        = 2
    Generate extra perimeters= NO
Print settings > Skirt and brim
    Don't use BRIM for big-gear and washers!!!
    Brim essencial for Idler, recomended for the rest

==>> For 0.25mm layers:

Print settings > Layers and perimeters
    Layer height                = 0.25 mm
    Horizontal shells, Solid layers    = 4 (aprox 1mm)
Print settings > Advanced > Extrusion width
    Default extrusion width        = 0.50 mm
    First layer                    = 0.48 mm
    Perimeters                = 0.48 mm
    Infill                        = 0.48 mm

==>> For 0.40mm layers:

Print settings > Layers and perimeters
    Layer height                = 0.40 mm
    Horizontal shells, Solid layers    = 3
Print settings > Advanced > Extrusion width
    Default extrusion width        = 0.60 mm
    First layer                    = 0.58 mm
    Perimeters                = 0.58 mm
    Infill                        = 0.58 mm

There is some rounding problems and 0.48 or 0.58 allows for better thin walls

May I ask what variations I'll have to make to obtain a version for 1.75 mm filament?
It was not mentioned in the instructions and I only have 1.75 mm filaments
Anyone looking for the clothespins listed, here's an Amazon link: amzn.com/B000HJDCWW
Hi,

I like your Version of this Extruder. But is there a version for 1.75mm filament?
I´m not able to change it by my self.

Thanks
Hi, I think this is a great design. Can you generate a mirrored design? I am going to use this on a Mendel90.
Is a simple mirror image all that you need? This can be done wit Netfab-free (I just checked) available at netfabb.com/download.php.
I believe that only the extruder body end the idler need inverting.
If you need something else, please ask again...
I printed this and am a bit disappointed.

1. You shouldn't have changed 3mm to 2-56 ..nearly everything on reprap is 3mm and introducing another screw size was plain unnecessary.

2. The gears are too thin --- toooooooo thin...I have broken nearly 4 small gears off the original wide design .. .(about 100 hours of use each) .. and I don't think the thin gears will last

3. Your idler design is made with support .. why? you can rotate it 90 degrees and it needs no support.

4. I like your quick eject idea ...but there really was no reason to change the item 1, 2 ..... I don't think it's an improvement .. it's a true tangential fork. If you would post another design with 3mm and wider gears .. I will surely try them.
I printed this and am a bit disappointed.

1. You shouldn't have changed 3mm to 2-56 ..nearly everything on reprap is 3mm and introducing another screw size was plain unnecessary.

2. The gears are too thin --- toooooooo thin...I have broken nearly 4 small gears off the original wide design .. .(about 100 hours of use each) .. and I don't think the thin gears will last

3. Your idler design is made with support .. why? you can rotate it 90 degrees and it needs no support.

4. I like your quick eject idea ...but there really was no reason to change the item 1, 2 ..... I don't think it's an improvement .. it's a true tangential fork. If you would post another design with 3mm and wider gears .. I will surely try them.
1. The change was *not* from 3mm but to 4mm long screws. As said, this is for Brazil only. If you are not from here, please, just ignore the file. My friends loved it ;-)
2. This is not a beginners print. If your printer is not yet calibrated, ask a friend and print again when your printer is better calibrated. Use 0.25mm layer with the settings in the instructions and it will be very strong.
3. As explained in the text, when printed on the back it is fragile. Printing on the side is more trouble but has superior result.
4. The idea of the quick release is not mine, have you read the "derived from"? and I don't even understand what you dislike about my implementation.
Allain
I have reasonable exp. with printing .. have 2 printers and printed nearly 1000 hours of ~100 different designs.

I have 2 issues with your design.. The gear you designed is thinner than the older design -- much thinner, maybe someone before you did this change. As this site has lost credibility .. good designers have removed their design ..Simon/Prusa others.

I have used Simon design with 3mm bolts.. not a problem!
I did the big gear a little thinner. It is still much wider then the original "straight" gear, so this is absolutely not fragile.

I don't know what you don't like about this gear, it was much praised... If you have real criticisms and specialy constructive ones, you are wellcome and I will improve the design.

BTW, there was an error in the first comment. The fast-release screw was never 3mm, but it is opcionaly 4mm. and that for non-brazilians only.
Having trouble finding 5/32 screws. Can you provide a link for reference? or a source? Thanks
Sorry for the delay. I asked for help from a friend that works in the US and apparently that screw only exist in Brazil !!!

There already is an option in the SCAD file for M4 screws, I don't know if M3x60mm screws are available there but I used threaded rods with nylock nuts in place of the screw head.

The only difference between the 2 options is the nut housing which is bigger for M4 then for 5/32" nuts. If you have problems, I can upload a set of .STL files for that, just ask...

If there is a more convenient screw available I am willing to include it as an option too.
BTW, I just assumed that that is an US problem, your profile is incomplete in that aspect.
Thanks for the reply. Yes they are not to be found here in the us. M3x60 are also hard to get. I have some on order but no idea when they will ship. I will go with M4 thanks again.
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