Fan duct and Mini Differential IR sensor v1.1 mount for E3Dv6 hot end on Kossel

by dc42, published

Fan duct and Mini Differential IR sensor v1.1 mount for E3Dv6 hot end on Kossel by dc42 Jul 24, 2015
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This is for mounting a 40mm hot and cooling fan and Mini Differential IR height sensor board version 1.1 (see https://miscsolutions.wordpress.com/mini-height-sensor-board/) on a Kossel with E3Dv6 hot end.

Updated 2015-08-17 to raise the sensor board by 0.5mm and add alternative effector mounting hole centres. The STL file suffixed -mk is for the Mini Kossel effector, the one suffixed -rd is for the Robotdigg aluminium effector.

Updated 2016-06-25 to enable Customizer and to provide an option for the larger E3D heater block that accommodates a PT100 or thermocouple temperature sensor.


This design places the version 1.1 sensor board below the heatsink of the E3Dv6 hot end, allowing the sensor to be placed closer to the nozzle. When printed without support, the bridge may be a little messy, but you can clean up the worst of it with a file and the rest will be hidden by the cooling fan. To assemble, first check that the print will fit easily over the groove of the E3Dv6 and file the print if necessary. Mount a straight 3-pin PCB header on the component side of the sensor board. Trim the pins and component wires on the back of the board. Attach the sensor as shown using two M2.5 countersunk screws, then cover the back of the board with 2 layers of Kapton tape. Fit the printed part over the groove of the E3D with the narrow part of the heater block facing the back of the board and parallel to it - DO NOT grip and twist the heater block to align it or you may damage the heat break. Fit a 40mm x 10mm cooling fan on the front.

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It looks like the sensor board is lower than the nozzle tip...do you calibrate the bed and then remove the sensor? Or am I missing something?

The bottom of the sensor board is 1mm higher than the nozzle tip.

Got it, thanks. Was thrown by that fifth photograph...

any way to add cooling fan for filament

I work in Autocad & I'm not sure how to convert this scad file so that I can import & modify this part to fit my E3D Wanhao D6 extruder base.
Is there any file format you can think of that you could export this too?


You can convert .scad files to STEP format using Freecad.

Comments deleted.

Just ordered the duet wifi and your sensor board . While waiting for its arrival im looking into sensor mounting options on my E3D V6 ( standard 12VDC cartridge and NTC bead).
Your design shows the sensor very close to the heater block ! Does this work OK ?? Apologies for being sceptical but id rather ask 10 stupid questions than ruin my new sensor
I intend to design an adapted version of this http://www.thingiverse.com/thing:510957

E3D v6 integrated fan layer

On a delta printer especially, the closer the sensor is to the nozzle the better. The sensor is rated for operating temperatures up to 85C. The main thing to be careful of is that the hot end can't rotate and cause the heater block to short out the connections on the underside kf the sensor. HTH David

Thanks for the quick reply David . Sorry i didnt mention i will use the sensor on my i3 steel . Ill probably end up designing a new mount for the sensor but thanks for the heads up on what to watch out for. Cheers

Do you use any print cooling fan?

Not yet. it's on my todo list to add one.

Any chance you'll be designing one of these that will fit a non-E3D J-Head?

My design for mounting the version 1,0 board on a Jhead hot end is at http://www.thingiverse.com/thing:883569. You would need to lower the mounting hole by about 1mm for the version 1.1 board, which is shorter.

Kossel fan duct and IR sensor mount for J-head hot end
by dc42
Comments deleted.


What's the correct position on the sensor to measure the probe offset from please? What offset values do you use?


Hi Paul, if you mean the XY offset of the sensor from the nozzle, the sensitive area is about 11mm to the right of the left hand edge of the board as pictured here, and 4mm in front of the face of the board.