All metal direct drive (no bowden) for BMG extruder and E3D v6 heatsink

thingiverse

<h3>UPDATES: </h3> The updated version includes the following features: - Base is in two parts for easier disassembly - the base is even more easy two install than the previous version - a new part heatsinkDeflector.stl for better heatbreak cooling - dimensional adjustments - option to mount a cable chain (can be mounted on BASE_part2.stl) - better cable management for the heater and thermistor - assembling instructions with pictures in pdf __TESTED ON: TEVO Tornado , feel free to modify for your printer (there is a .step file attached)__ Use the 2.6mm version of the base for carrier plates that are approx. 2.6mm thick and the 3.1mm version for thicker carrier plates (the 2.6mm version is apparently a little too loose, I'll try to fix that within a few days). Please write in the comments if anything is too loose or to tight, also, please specify which printer you are using and the thickness of your carrier plate. I've only updated the E3Dv6 version. The version for the Volcano hotend will follow shortly. I've taken the previous version for the Volcano down to avoid confusion. If anybody wants it before the updated version is uploaded please contact me and I'll send it to you. I've also deleted the previous instructions with videos. All instructions that are needed can be found in the attached PDF file. Comments and critics are appreciated! Please write in comments if you've tried this on a different printer than TEVO Tornado or CR10 . <h3>UPDATES: I've updated the BASE_E3D and BASE_Volcano files since I got some feedback that some versions (different clones have slightly different dimensions) of the BMG don't fit into the mount. Also, you can adjust the Z position of the BMG now - can also be used to fine tune the Z position of the nozzle.</h3> <h3>UPDATES: I've update the body and fanduct to fit on a volcano hotend (files base_volcano.stl and fanduct_volcano.stl). I haven't tried to assemble it for a volcano hotend, but it was told to me it fits. Please leave a comment, if there's any troubles.</h3> <h1>OVERVIEW</h1> This is an ALL METAL DIRECT DRIVE for the E3D v6 and BMG extruder (FULL DIRECT DRIVE, NO BOWDEN NEEDED!) for the standard carrier found at TEVO, CREALITY, and many other printers. I've tested it only on a TEVO Tornado, but I assume it should fit on any printer with the same carrier - see attached photo (CR10, Ender 3,...). The following guidelines were considered when designing this extruder mount: - it should be a full all metal direct drive (with no bowden at all) - reduced cloging (been printing for 2months with this extruder - several prints longer than 70h, 230°C, PETG, 60%fan - and had zero clogs) - optimized airflow under the nozzle for good bridging - no direct airflow to the heating block - a good cable management solution - accessible nozzle for an easy nozzle replacement - easy attachable mount to the carrier A CFD (Computational fluid dynamics) analysis was done to optimize the airflow in the Fanduct. Results are better without the silicon sock on the heating block. <h1>HINTS AND RECOMMENDATIONS</h1> If you have a printer with a large build volume and only one Z axis the first few layers won't be that good with this extruder. So I recommend to use the extruder on printers with TWO Z AXIS. I've manually added an additional Z axis and a stepper motor on my TEVO Tornado, since it only has one in stock. __DON'T FORGET TO CHECK IF THE HOMING LOCATION IS INSIDE YOUR BUILD VOLUME. OTHERWISE, YOU SHOULD MOVE YOUR Y LIMIT SWITCH (FOR 7mm).__ __PLEASE ADJUST THE Z LIMIT SWITCH BEFORE FIRST PRINT!!!__ IF THE STEPPER MOTOR IS RUNNING IN THE WRONG DIRECTION YOU'LL HAVE TO INVERT THE STEPPER DIRECTION IN THE MARLIN FIRMWARE (the BMG extruder runs in the opposite direction than most of other extruders)!!! There are already alot tutorials out there on how to do that, just google something like: "How to invert the stepper direction in marlin". __For good quality prints and to avoid clogging due to retraction don't forget to LOWER YOUR RETRACTION DISTANCE AND SPEED FOR THE DIRECT DRIVE (3mm with 20mm/s should be enough, since the direct drive has a much more effective retraction than a bowden extruder)!__ When printing the fan duct, don't forget to put supports to "from bed only". Also, for printing the part "BODY.stl" no supports are neceassary. However, if you do use supports on that part, check that they're not in places, where you won't be aible to remove them after the print is done. Print with at least 70% INFILL for best results! All cables can be attached to a GX16 8pin aviation plug. This way you can easily dettach the whole extruder from the carrier. However, using the aviation plug is optional, there is a separate cable holder on the base for regular cable management. The GX16 8pin connectors are available on amazon (or any other shop with electro material). <h1>ADDITIONAL SCREWS</h1> You'll need some extra M3 screws and nuts to mount everything together: - 2 x M3 nut - 1 x M3 15mm screw - at least 2 x M3 25mm screws (for the 4020 fan) - 1 x M3 40mm screw (for the cable holder) - 1 x M3 10mm screw (the stock one is ok) - 3 x M3 40mm screws (the stock ones from the BMG extruder are ok) 3D printing with Craftrum All Metal Direct Drive E3D v6 BMG extruder head EXAMPLE: https://youtu.be/ltZ0IbMaziA BLTouch offset from the nozzle is 35mm in x and 9.5mm in y direction. You'll need an additional m3 screw and m3 nut to fix the BLTouch mount to the base. <h1>LINKS TO PARTS</h1> When searching for parts use the following keywords: - for the HEATSINK: E3D v6 1.75 direct (or short distance or short range, also "J-head v6" for copies only) - for the THROAT: E3D v6 all metal 1.75 (or titanium), M6/M7 threads (M6 on one side and M7 on the other), 22.5 or 22mm length - for the aviation plug: GX16 8pin aviation plug Other parts shouldn't be that difficult to find, however, here are some links: ORIGINAL E3D v6 (bundle): https://e3d-online.com/v6-all-metal-hotend BMG Extruder: https://www.bondtech.se/en/product/bmg-extruder/ COPIES HEATSINK: https://www.aliexpress.com/item/4000038794570.html https://www.aliexpress.com/item/32682607195.html https://www.aliexpress.com/item/4000046308497.html https://www.ebay.de/itm/292317444309 THROAT: https://www.aliexpress.com/item/4000330393819.html https://www.aliexpress.com/item/33024437606.html https://www.aliexpress.com/item/32853548000.html https://www.aliexpress.com/item/33050387631.html https://www.aliexpress.com/item/4000036023809.html HEATERBLOCK: https://www.aliexpress.com/item/32816041972.html HEATER: https://www.aliexpress.com/item/32960167491.html BMG EXTRUDER: https://www.aliexpress.com/item/32917029058.html https://www.aliexpress.com/item/4000419512195.html https://www.aliexpress.com/item/32968490957.html NOZZLES: https://www.aliexpress.com/item/32835656952.html SILICON SOCK: https://www.aliexpress.com/item/32916210903.html THERMISTOR: https://www.aliexpress.com/item/32947495788.html 4020 FAN: - 24 V: https://www.amazon.de/dp/B00MNJD8BE - 12 V: https://www.amazon.de/dp/B00MNJD73I 5015 FAN: - 24V: https://www.amazon.de/gp/product/B06XCVGDCX - 24 or 12V: https://www.amazon.de/dp/B07DB7DLMM AVIATION PLUG: https://www.amazon.de/dp/B07NYYKQVZ https://www.amazon.de/dp/B07TV5YSJW