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E3D v6 Bowden extruder for Wanhao Duplicator i3

by JonBAL, published

E3D v6 Bowden extruder for Wanhao Duplicator i3 by JonBAL Apr 12, 2016
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Summary

E3D v6 Bowden extruder for Wanhao i3

This include holders of step motor to top frame, x-carrage block for E3D and more.


Need to buy

  • E3D v6 (j-head) hotend for 1.75mm (include cooling fan, hotend fitting)
  • PTFE tube for 1.75mm (1 meter) with cold end fitting (I use 0.5m only)
  • Kit of nozzle for E3D v6 (line is very wide, from 0.2 to 1.0mm)
  • Fasteners (M3 and M4 nuts, screws of different lengths)

Mounting of the stepper motor

It is possible to mount of stepper motor on the top of printer's frame only. May be I design a mount for another places.

Holder v1.0 include

  • Step_motor_holder_frame_v.1.0_nut.stl - 2pcs
  • Step_motor_holder_frame_v.1.0_rest.stl - 1pcs
  • Step_motor_clamp_v1.0.stl - 1pcs
  • M4 nuts - 2pcs
  • Short M4 screws (9-10mm) - 2pcs

Holder v1.1 include (more difficult to print than v.1.0)

  • Step_motor_holder_frame_v.1.1.stl -1pcs
  • M4 nuts - 2pcs
  • Short M4 screws (9-10mm) - 2pcs

Cold end

I use:


Extruder E3D v6 mount

X-axis belt holder is mount on bearing block:

  • E3D_hotend_base_v1.0.stl (need add support in nut's holes) or E3D_hotend_base_v1.0_wSupp.stl - 1pcs (infill 50-60%)
  • E3D_hotend_clamp_v1.0.stl - 1pcs (infill 50-60%)
  • X-axis_endstop_holder.stl - 1pcs
  • M4 nuts - 2pcs
  • M4 screws (40mm or more) - 2pcs
  • M3 screws (7-8mm) for x-endstop holder - 2pcs
  • Stock M3 screws for mount cable chain - 2pcs
  • Stock M2 screws for mount x-endstop - 2pcs

X-axis belt holder is mount on screws in back side:

  • E3D_hotend_base_v1.0.stl (need add support in nut's holes) or E3D_hotend_base_v1.0_wSupp.stl - 1pcs (infill 50-60%)
  • E3D_hotend_clamp_v1.0.stl - 1pcs (infill 50-60%)
  • X-axis_endstop_holder.stl - 1pcs
  • M4 nuts - 4pcs
  • M4 screws (40mm, not more) - 2pcs
  • M4 screws (20-25mm) for back side - 2pcs
  • M3 screws (7-8mm) for x-endstop holder - 2pcs
  • Stock M3 screws for mount cable chain - 2pcs
  • Stock M2 screws for mount x-endstop - 2pcs

What else need to start?

You need desicion few questions:

  • If you install this extruder, than change height of nozzle. It will be higher than stock extruder. You need move the Z-axis endstop below. Not more Z-axis adapter can move down. I desing this simple adapter, you can use it. Print this before installing extruder!
  • It is not critical. In this extruder nozzle misses on the bed. You can make Y-axis endstop adapter and fix it.

Modifications

You may have noticed a lot of holes in mount extruder. This is done for easy mount additions and need M3 screws (7-10mm).
You can make Wire_clamp.stl for fixing wires.


Cooling

I make the adapter (Fan_holder_for_saldots_design_v1.0.stl) for saldot's desing fan holder. One adapter include:

  • Fan_holder_for_saldots_design_v1.0.stl - 1pcs
  • M3 nut - 1pcs
  • M3 screw (20mm) - 1pcs
  • M3 screws (7-10mm) - 2pcs

And I design mount for radial fan 50mm, it is very efficient. But printing is not simple: you should be able to make bridges.

  • Radial_fan_50mm_mount_v1.0.stl - 1pcs
  • M3 nut - 1pcs
  • M3 screws (20mm) - 2pcs
  • M3 screws (7-10mm) - 2pcs
  • Radial fan 5015 (size 50x50x15mm) - 1pcs

Problems

Maximum printing height is main problem in this realise. Height 160mm is limit for non-problem printing. If extruder lifted higher than 160mm, then PTFE tube rubbing the stepper motor.
In the feature I desing new mount for stepper motor. This will increase the height of the print.


Give back "I Made One", please. This is pleasant for designers))

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can you attach the file for a regular fan like you have in the pictures. Thanks!

Is the stock stepper strong enough for a Bowden extruder?

I'm using the radial fan adapter and getting a lot of stringing using a 50mm radial fan.

http://i.imgur.com/HWqAJjE.jpg

Comments deleted.

are you using printed ingus bearings and bearing block? how do they fit?

Comments deleted.

I say it need only one stl-file from Wanhao Mk9. Print it, and be happy)

Started the conversion on my malyan m150 today but I have one problem, how to mount the belt?

Mount the belt is not apply to this mod.
You can see my method: http://www.thingiverse.com/thing:1428012

Modified belt holder for Wanhao i3 X-Axis Belt Tensioner
by JonBAL

Seems like I need to improvise a temporary solution because my extruder is broken so I can't print and have to do this mod earlier then planned.
Will post the temporary solution when I'm done.

Дорогой автор, спасибо за данный мод, но вы не учли Усадку ABS. В итоге все детали не подходят.
1)Часть, которая одевается на раму принтера под катушкой - пад в губах вал - рама не влезает,
2) сама рамка на 1мм короче чем рама - не одевается.
3) лучше убрать дыры (ромбы) Экономия пластика незначительная, а вот время печати увеличивается колосально
4) Обдув - потолок длиной трубы плоский и пластик экструдируется на весу в итоге на потолке куча соплей внтрури трубки что ухудшает прохождение потока. Стенки должны быть / -образными
5) кулер не влезает в отверстие под него опять же изза усадки ABS + дырка под нижнее ушко не там получается
6) не делайте дырки под винты 2.5мм их нереально найти! делайте под 3мм!

Ну во первых, этот сайт международный и комментарии принято писать на английском.
Во вторых, вас не смущает тот факт, что мод успешно повторён уже не одним человеком, и никаких проблем у них не возникало? С некоторыми я общался по поводу результатов и доработки мода.
1,2) Всё влезает
3) Если не хотите ромбы, то для вас есть другая версия крепления, и ещё одна версия в комментариях
4) Тут согласен, но "куча соплей" это проблема настроек
5) У всех влезает, а у вас нет
6) Дырки как раз таки под винты 3мм.

Rombic holes - my mistake they save time.. - Ok Here!
What wall thikness must be used then?
Small holes on sides for cooler mounts - 2mm bolt slide free - 3mm too big for holes - 2.5 is right
The two big holes that lock radiator - 3mm bolt slides free - need 4mm bolt
My radiator just like yours but it doesnt fit in clamps. Had to cut off radius of 0.3mm more.

I measured your model of motor mount (goes on top)and it is 50mm sharp - frame is 50mm wide. You cant print ABS 1:1 - it will shink 0.5-1.5mm guaranteed.

Does this use standard prusa i3 spacing on the X carriage? really great design, very versatile with all the mount points and such.

Wanhao i3 has 45mm betwen center of rods (on x-axis). I think it compatible. Measure your size.

What are some of the benefits of using this extruder over the stock? Besides printing at higher temps and less strain on the stepper from all the heat generated while printing ABS.

  • Different nozzles: 0.2-1.0 for simple hot-end, 0.4-1.2 for volcano hot-end (very fast)
  • Low cost nozzles
  • Less weight (moves)
    may be else anythink...

I need cheap different nozzles and make it)

This mod does not change the printing volume if we ignore the tube rubbing, right?

I mean, it is still 20cm X 20cm X 18cm, right?

Yes, if we ignore (replace stepper motor from top frame) volume doesn't change.
I added the photo. You can see gaps with Z=180mm.

Awesome, thx :)

Do i need to update the firmware?

Don't need update the FW. All work with stock firmware.

kinda a odd place for the motor/extruder. this is where i mounted mine. http://www.thingiverse.com/thing:1489794

Simple Wanhao i3 Bowden Mount

I think short PTFE tube is better (my desing need 0.5m only). Therefore more fast retractions.

I have no problems with retraction. but my tube also had much less bend/flex then yours. just a bit longer.

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