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Giova's Extruder

by GiovaGio, published

Giova's Extruder by GiovaGio Mar 22, 2016
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Summary

The goal of this project, started in Spring 2015, was to create a cheap and lightweight extruder, the first choose was "24BYJ48", substituted with "28BYJ-48" (Fig.1) because stronger, cheaper and easy to find.
This stepper motor is unipolar and it needs to be modified to become bipolar, there are 2 methods: the first method consists by unmounting the case (Fig.2). the second consists, in a faster and less invasive method, by cutting the plastic case and PCB, i suggest this method (Fig.3).

You need:
x2 - 28BYJ-48
x2 - 40mm fans
x4 - M3 screws + nuts
x4 - M4 30mm screws + nuts
x5 - M4 20mm screws + nuts
x2 - MK8 drive gear for 1,75 mm filament
x2 - 605 2RS 5X14X5 bearings
x? - M4 washers
The connection to RAMP 1.4 must be modified (Fig.4), the connector of second extruder is inverted connected

Assembly: (Fig.5)
(Tolerance is always 0,5mm excluding Hot-Ends connectors)
Idlers are different and they are marked with L or R letters visible in the model, the washer is used to centering the bearing with drive gear (fig.6).
Hot-Ends connectors dimensions are copied from Greg Wade's extruder, their distance is 23mm.

How to use it:
This motor is slower, fragile and weak compared to NEMA17, plastic gears inside it can be easily damaged, so the Hot-End temperature must be increased to soften more the filament (in my tests i use PLA at 210-220°c), maybe the print speed will need to be slower, another problem with this motor is the pression of idler, if less the filament is not pulled into Hot-End, if too much the motor don't go, you have to find the right distance, i suggest to add washers at idler regulating screw to fix at the right distance you found, so u don't need to find the right distance everytime(Fig.7).
Top fan is needed because the motors overheat fast, motors drivers power should decreased because these motors need less power then NEMA17.

Settings:
Steps per mm are ~1500
Max speed is ~8mm/s

Problem/Solution:
The motor don't works: wrong wiring, filament idler pressure is too much, speed is too fast, driver power is too low, it's broken.
No filament extrusion: filament idler pressure is too much or less, Hot-End temperature too low.
Filament extrusion is unstable or stops after a while: filament idler pressure is too much.
Layers are not uniform/bad looking object: try to increase temperature(Fig.8).

Other objects in the photos:
http://www.thingiverse.com/thing:1434161
http://www.thingiverse.com/thing:1407251
http://www.thingiverse.com/thing:1000841
http://www.thingiverse.com/thing:711671
http://www.thingiverse.com/thing:510508
http://www.thingiverse.com/thing:10915
http://www.thingiverse.com/thing:761806

Print Settings

Rafts:

No

Supports:

No

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