Hey! This thing is still a Work in Progress. Files, instructions, and other stuff might change!

PG35L extruder for Kossel

by Johann, published

PG35L extruder for Kossel by Johann Jan 20, 2013
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PG35L extruder for Kossel by Johann is licensed under the GNU - GPL license.

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This is based on MendelMax J-Head Micro-Extruder V5 but completely rewritten in OpenSCAD and slightly modified for Kossel:

  • Two 623 (3x10x4mm) bearings to support the drive gear, attached with M3x20mm.
  • 16mm GrooveMount (compatible with J-Head and MakerGear).
  • M4 mounting screws, 50mm center-to-center.
  • Hotend exactly centered.


Latest source on GitHub: https://github.com/jcrocholl/kossel

Works with the V4 idler: http://www.thingiverse.com/thing:39098

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What effector is being used there? It looks different than the one in the github archive.

Hi Johann,
Thank for your great design !
I wonder , which effector platform are you using ?



Hey, just looking at this, I'm a little wary of the added weight to the print head assembly, and the torque that the side-mounted motor might place on the print head platform. Based on that, I have a couple of questions.

  1. Are you seeing any added print head "wobble" due to the weight and the inertia it creates?
  2. Did you look at mounting the motor with the shaft perpendicular to the z-axis and aligned with the center of the print head? Just brainstorming, it seems like you could raise the motor up an inch or so, and build a really short Bowden tube to direct the filament into the J-head. Or, maybe the torque isn't a problem?
    Also, I assume that the point of this is to enable the Kossel to print flexible filament, right? Any other benefits to this?

Dear Johan,

the utilbots hardware kit and gear will fit your design?http://www.ultibots.com/micro-extruder-v5-hardware-kit-3mm-drive-gear/http://www.ultibots.com/micro-...

in the kit there are this components:

M3x30 bolts and M3 jam nuts for the idler (x2)
M3x25 bolts and M3 jam nuts for the motor mount (x2)
624ZZ bearings for internal body (x2)
624ZZ bearings for idler (x1)
M4x20 bolts and M4 jam nuts for the idler bearing (x1)
M4 washers either side of idler bearing (x2)
M4-20 bolts and M4 jam nuts for the internal bearings (x2)
M4-10 bolts and M4 jam nuts to secure to x-carriage (x2)
M4 washers either side of internal bearings (x4)

thank you and congrats for your work!

Johann. Thank you for the Rostock printer. My friens and i are about to make three printers with some changes. We have called it Trigobot and is a collection off all the best parts fro the Rostock and Kossel. We use a modifed micro PG35L-048 extruder but have changed to a http://2engineer.com2engineer.com motor due to difficulties to find the PG035l motor, We have also added some more aluminium to get som more weight on the frame. We will add the printer to thingerverse when builded

To reduse modelling, is it possible for you to add the base plattform you have in the main picture in this "V4 idler? How manny positions do you have,,,,is it 20 holes?

Hey Johann, I think the V4 idler got taken down.

Hi Johann - is the laser-cut groovemount in the picture a custom part? Even if so, I'd be interested in the DXF to mill one out. Thanks!

Johann -
How hot is the motor running? What speeds are you pushing filament? And retract?
Thanks - Brad

Do you have an OpenSCAD file for the idler, or are you just using the one from Ultibots' extruder? I'm curious because I don't have any 605 bearings around.

I'm using the V4 idler - works fine, other than needing some hole drilling to clean supports out!

Two questions.

  1. Short shaft or long shaft pg35l?
  2. Filament diameter?

I'd also like to hear if the motor end is hitting your delta arms as was already asked.

Congratulations, you have discovered the main two reasons for this thing:

  1. I have the $7 short shaft PG35L and that's why we need the two idler bearings behind the drive gear.

  2. I rewrote the extruder body in OpenSCAD to make it easier to change things like filament diameter. The attached STL file is for 1.75mm filament but you can adjust it to 3mm filament by changing a single line in the .scad file.

Yes, the motor was still hitting the delta arms, so I'm working on a slightly larger end effector to move the arms out of the way.

Most awesome of answers. Exactly what I'm looking for.
Do you think if I offset the hot end a bit more off center, that this would move the motor out of the way? I was experimenting with my hacked up Ultibots microstruder, and cut a semicircular bit of the printing platform to be able to move the hot end over approx. 6mm beyond the edge of the center hole of the platform.

What do you think?

I think it's better to keep the nozzle centered because delta geometry calibration is already tricky enough. :)

My new larger end effector (moving platform) allows rotating the extruder a few degrees around the vertical axis, to make the backside of the motor stick out exactly in the middle between the pairs of diagonal arms.

Johaan -
I like the adaptation. Kossel is on my radar!
What springs are you using and how long are your idler bolts?
Thanks - Brad

I was using the original springs from my MakerGear Prusa brutstruder/stepstruder, with M3x40mm screws. But now I stopped using the springs and shorter screws are working fine so far (I think M3x25mm).

Nice, printing a groove-mount adapter for this now - I'll post it when I've tested it. 159 grams with all the hardware installed! The bearing "housings" are a bit loose on the idler - using a 605zz.