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Nano-Extruder PG35L (uniX V2 System !)

by Chri, published

Nano-Extruder PG35L (uniX V2 System !) by Chri Jul 29, 2012
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Summary

The Micro extruder was not small enough (still over 70mm) for me so i designed a new body from scratch.

With the smaller size a new uniX-hotend V2 assembly version is released !

Features:

  • very compact design, only 50mm tall !!!

  • Overall weight of complete extruder with hotend can be under 200 gramms !

  • uni-X V2 Universal Hotend system -> Works with alot of different Hotends
    (no need of a metalplate for V9/v10 Hotend anymore !!!)

  • 50mm assembly holes

  • should work with 3mm and 1,75 material (using brass tub insert)

Still missing: fanmount -> can be used from a other PG35 extruder.

  • i already made some specific hotend derivates from this with only 43mm height, maybe i`ll release them later (some weeks)

Instructions

EDIT: fixed version uploaded -> added support to upper Filamentguide.

EDIT2: uploaded some bearingholderfor the extrudershaft.

Testprint was made with 0,35mm layerwith and 0,28 layer height.

Zip contains again a set of 16,4mm insets and one with 16,7mm (for well tuned printer ;) ).

Vitamins:
1x PG35L Stepperdriver
1x MK7 Pulley or similar
6x M3 nut
4x M3 washer (some additional springwasher for extruder recommended)
4x M3x40 screw
1x 624Z bearing
1x 3x14mm bolt (for idler bearing)
2x small springs for Idler
2x M4 Nylock nuts + screws for mounting the extruder on the carriage

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I've been having problems with my PG35l motor. I have to set my extruder acceleration down to 500 mm/s^2 in the firmware in order to get retraction to work, but then my print quality suffers. I have great quality at 1200 mm/s^2 but no retraction. My actual retraction speed is set at 20-30 mm/s. My ability to retract seems to depend on how high I set my extruder acceleration in the firmware but is also affecting quality. Have you ever had similar issues? Thanks for the help

I'm afraid I'm in the same boat as rrhb - I don't know what the insets are. I like the extruder design, but there is a hexagonal hollow inside of the body that appears to serve no purpose (other than to create a space for the filament to get kinked in). Does this somehow get filled in by the inset?? Are the insets meant to be printed separately and then inserted into the body, or are the somehow merged as meshes and sliced together? I also don't understand the difference between the 16.4 and the 16.7 insets and why the 16.7 would need a better-tuned printer. I feel somewhat dumb for asking these questions, but there really are no instructions given here.

Hy

the Hexagonal Part is the size of a M10 Nut, this was to mount the V97V10 Hotend (look at the second picture the right hotend) at first, but is not necessary anymore, the second reason is to make it this deep (20mm) is to put some long hotends into it (Stoffel`s V1 for example).

If not used you can print the hex dummy (and the other inserts) separatly and put it into the extruder as you thought right.
If you use 1,75mm filament you do not need to print it as you can use the brass insert to bridge over the space.

i missed it to explain the hex hole, i added a picture to show it to you.

the two inserts types are the two dimensions of them, one set is with 16,4mm diamenter the other 16,7mm. as the body also has 16,7mm there ma be some people who are not able to put in the 16,7mm version into it printed with their printer.

are the insets meant to be put inside the the body to allow the base of the extruder hole to reach the hot end? that would make sense - but i'm not 100% sure that is the intention.

Hello Chri

I really like your design and want to put it into my Solid-work assembly. Any chance you can upload a file that I can take into Solid-works?

Terje

You have killed your motor.
Probably the motor was too hot and now is the collapsed magnetic field.

About where is the sweetspot from the polou drives? Setting mine up next week and having a hard time finding the info about this?

What current as you feeding it with?

I am having a difficult time finding the sweet spot: Below 300mA I do not get consistent extrusion but above that it will heat up quite quickly.

Thanks.

Nice work thanks. Trying to put this together with a V10 mendel parts hotend using the V9 mounts you deliver, we'll see if it fits. Hadn't so much fun printing with skeinforge+support until now . trying without support now.

well looks like you forgot to add this support layer between the upper, smaller hex hole and the filament hole - the bottom one works well but there doesn't seem to be one for the upper one. this is where printing without support fails - at least for me.

Tried slic3r and skeinforge.

With support it works but it's hard to clean.

there is a 0,5mm supportlayer in between , what printsetting do you use ?

Chri

yes, there's a support layer between the big round hole and the hex but there is no layer between the hex and the upper filament hole which makes the ceiling of the hex drop down :)

i used a layer height of 0,25 with a 0,35 nozzle but tried to change layer heights to your settings - of course this didn't change anything - just tried. Am now trying a print with support and a 0,5 nozzle (0,30 layer height). But the support makes it a nogo i guess. You can't really clean out the
hex very good. I also tried importing the stl into sketchup to add another layer in there but this breaks the stl and netfabb isn't able to repair it.

Can you probably add your source file here or at least add another support layer "upstairs"? that would be awesome 8-)

... and i guess those inserts shouldn't even be printable without support, shall they? The slot on the sides wouldn't work.

thx for the info, i just uploaded a fixed stl with the support for the upper filament parts :)

Yes the V9 Part needs support, all other parts don`t need them.

I don`t know if the Body will be usable printable with 0,5 nozzle and 0,3 layer height.

:) chri

thanks, mate :-D 8-)

Nice ! Could you make a version with holes for a Arcol v3 (http://www.thingiverse.com/thing:4632)http://www.thingiverse.com/thi... ?

Also, I heard (from ezmobius) that the micro extruder worked much better with a bearing at the end of the motor shaft to prevent the hobbed from moving (cf https://groups.google.com/forum/?fromgroups#!topic/mendelmax/e9I6ue6Xuys)https://groups.google.com/foru..., could you do the same on this model ?

Arcol.hu_hot-end_v3.0
by laszlo

Hy, sorry a Acrol V3 is not planned, it will just make things very complicated. (made already alot of troubles with my first universal extruder)

The thing with the bearing sounds interesting , i`ll check it out.
what bearing dimension is common for a 5mm shaft ?

mg Chri

Chri - in reply to

No because in my opinnion Openscad is only good for real parametric things like gears and pulley`s

For all other things openscad is the most worst CAD tool ever ...

Yeah, I wanted to print one of these without offset holes, with a different nut diameter, smaller filament orifice, and change the bottom to no nut holes and j-head depth mount. perfect use for a scad version of this.

Chri - in reply to

yes maybe if you want to change some parameters its cool, but try to draw the extruder itself it would be a pain in the a#* ...

Changing your told values would only take about 10 minuts with sketchup (even with importing the stl again)

why do you want to remove the nut holes ? wanna make life more difficult ? ^^"

there is a reason for the holes also have an offset, thats not just for fun.
check out the prusa xcarriage i
made, without them it would be very difficult to assembly all parts.

Nevermind. I see why the offset holes now. :)

Chri - in reply to

hehe, i`m too slow at writing ;)

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