Attached are a few photos of my current direction and experimentation with Mahor's extruder v3. I'm trying to overcome the following challenges with this new design:
Stability - the original design is a bit wobbly and flexible when mounted to the CR10, you can see in some of Maho's videos he has used aluminium to make the front and back plates, but as I don't have the tools to do this I wanted a 3D printed solution.
Dust and mess - if your active cooling is blowing air into the hopper and your printing with shredded wast plastic then you end up with bits of plastic getting blown everywhere. I wanted a different location for cooling (this is not a problem with pellets).
Prevent blockage - shredded wast plastic is very high friction and the pieces of it are very light so it dose not flow very well.
Make it easy to mount to my CR10 - now it mounts directly.
The design I have created also has some disadvantages too, its heavier, its much harder to print, it requires quite a lot of post processing and is much harder to assemble, so if your just printing with pellets and its stable enough for your use case then the original design would be easier to work with.
I printed the housing in Carbon-fibre PETG and the hopper in clear PETG. It was my first time using Carbon-fiber PETG but it printed very well and without problem, however it did take 26 hours on my FFCP! I will print more with this as it make super stiff, strong and light parts, better than anything I used before.
The stl's can be downloaded from here: https://www.thingiverse.com/thing:3032188