Plans for an Aluminum Mk8 Extruder Upgrade

by whpthomas, published

Plans for an Aluminum Mk8 Extruder Upgrade by whpthomas Mar 9, 2013



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For those of you who have a metal fabrication shop and what to give it a try, here are some plans for an all aluminium Mk8 extruder upgrade. The plans are intentionally simple so you can add additions as desired. STEP files for importing into other CAD programs are also included.


Study plans, machine and turn, then install.

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Trying to get a dual one of these working on my Mendel i2.... haha!

What type of Aluminum did you use?

Ok I want 2 of these...
yep yep

Good work sir!
I have used your printable version on my 2X. Unfortunately the Rep 2Xs run extremely hot if you have large builds. So, both ABS and PLA begin to warp after a couple of long prints.

The Big Question:
Does this work On a 2X?
I understand the handle on the side needs shaved off to fit next to the second extruder and needs mirroring for the left extruder, But, does all the other geometry fit the 2xs standards?
if so, let me know and I will start the ball rolling.

Need help my 2x is just too hot.

Bless you, sir. You saved my machine. I was getting RIDICULOUS unreliability with my new Replicator 2; and so I had my in-house machine shop make your Upgrade and it has worked famously without fail since! Thank you.

Does this use the same hardware as the plastic version by whpthomas?

Awesome, thanks for the reply and designs

Nice, but not really necessary. The printed plastic version works perfectly.

By varying degrees of necessary, I guess. I can easily machine aluminum, my current extruder head isn't reliable enough to make the printed plastic one, and I can make it quicker than I can get someone else to print one up, never mind the time it takes to mail the parts to me.

(Cont. stupid iPhone!!!!) hotter prints and strong spring warps the lever arm JUST enough to cause me to want a little more rigidity.

Hey whpthomas, I'm south of the border and wondering if you would at all be open to sending one down if I were to PayPal you some $$ for the effort? Your plastic design is great however I notice on hotter prints i

Afraid there are no plans for me to build an sell them, but others are looking into it so stay tuned - I will post here with links when they become available.

o bum, no worries thanks for the reply :)

Have you considered having a filament guide hole like the Makerbot version???

The whole point was to make it easy to machine.

Yes, I get that part. The MK8 upgrade you made saved my machine and I love it. But the only frustration I have is trying to get the filament passed the gear and down into the hole because the filament curves to the side. I'm getting better at loading it though. Just a thought. Thanks for responding.

There is a new version of the printable one with the filament guide if you haven't noticed - I should update the pictures.

Great! Thanks!

Also consider to have it printed in stainless steel by Shapeways...

Shapeway stainless has tolerances of +/- 2mm so not suitable. The part also doesn't pass their design rule suitability analysis.

They under-estimate the accuracy of their print! I printed much smaller/thiner parts, an they are OK;