Creality CR10 S5 to CoreXY (CrusaXY HB1)

thingiverse

Creality CR10 S5 -> CrusaXY HB1 = **UPDATE LOG** ___ **1/02/2019** -*Video Added* -*Pulley Mount IDEX right side UPDATED* - No endstop switch mounting, additional support for M5 bolt. **12/28/2019** - *Adjustable Motor Mounts V1.2 variations* - These files are bulkier than the original motor mounts, but shouldn't deform under continuous high temperature use, just make sure to print in the proper filament. Support material is required for these parts, align all pieces the same on the build plate. Additional cut out provided on left hand parts in case the belt was rubbing for you. -*Single and Double Dsub 15* - detachment point for an even easier manual tool change. Both parts require mounting to the rear extruder support plate. -*Rear Support Plate Variations added* - does not contain endstop mounting points, makes for an easier print. -*SuperVolcano Prusa Mk3 Extruder Plate* -*Prusa Mk3 Extruder Plate with built in Tensioner* - combines two previously posted files into one part, I found this version to be more effective at securing the extruder in place. *Extruder Wall Mount* - Can be mounted on the wall, or in the enclosure, this part will hold the extra extruders when not in use (must be placed there manually). **11/23/2019** - *Pulley Cover V2 (both left and right side non-IDEX)* - reuploaded, previous versions were missing a few cuts, if you printed these parts using previously downloaded files slight hacking will be required. - *Updated BOM* - More accurate and up to date, including hardware click > [here](https://docs.google.com/spreadsheets/d/1rqwowZmV7dKZnKJqoQckv2zRiyOCHZssdogx). - *Updated Print Part List* - See bottom of this summary. - *Idler pulley 5mm for zaxis* - Used when <=2 motors and 1 belt is used - *[Assembly Instructions r1.0](https://cdn.thingiverse.com/assets/02/13/e3/9a/68/Assembly_Instruction_CrusaXY_HB1_r1.0.pdf)* - The first revision of the assembly instructions have been uploaded. Some images and information is missing, typos may exist, but it still contains **lots of useful information and pictures** to help you determine what is involved in the build process. ___ ******ATTENTION****** There are multiple upgrades available for this 3D printer, these are the HB1 base files. A limited number of externally purchased parts are needed to complete this upgrade. If you would like to further upgrade this printer please refer to the following links: Enclosure: ***Link available shortly.*** [Geared Prusa Mk3 Extruder --> For Generic V6 and Prusa V6](https://www.thingiverse.com/thing:3972197) [Original Creality Motherboard Case](https://www.thingiverse.com/thing:3972327) [Duet 2 Wifi Upgrade (Required for subsequent upgrades)](https://www.thingiverse.com/thing:3972300) [IDEX System](https://www.thingiverse.com/thing:3974999) High Temperature Extrusion: ***Still under revision.*** CNC/Laser Adaptation: ***Still under revision, many of these files will completely replace the original HB1 files.*** ___ Reasons behind building: I purchased the CR10 S5 to use the maximum build volume of 500x500x500 mm cubed, however due to the H-bot design of this printer and cheap Chinese design, I had a very low success rate for prints (around 10%). In all honestly, I was starting to think that purchasing this machine was a waste of money and there was no hope for it, therefore I set out to make the machine not only usable but outperform my Original Prusa i3 MK3s. Some of the files in this project were inspired or used from User: Greg191134 and his design: [Creality Ender 4 – CoreXY Conversion](https://www.thingiverse.com/thing:2686559). Other parts (like the extruder housing/design) are modified versions of the original Prusa STL files for the MK3. The goals of this project were to remove the following problems from the original CR10 S5: 1. Inconsistent extrusion caused by poor Bowden/J-head extruder design. Heat creep, stringing, blobbing, and surface scars would often appear in prints. 2. Poor bed leveling design. With the OEM setup, the bed was very hard top get level, stay level and use consistently. 3. Incapability to print at speeds above 40 mm/s (even for infill). When printing a large print that requires support material, the added inertia to the print from the build plate shifting forward and backwards would cause support branches and parts of the print to become dislodged or removed from the print bed. 4. Low detail in models and prints were often produced with poor tolerances, making many parts completely unusable. 5. Wobble. Every axis (XYZ) had an insane amount of wobble. I use small bobble heads purchased at street fairs as vibration sensors on the machine, and many times when running a print at 70% speed there would be enough motion to knock the bobble head off the machine. This is NOT GOOD. 6. Flex. Particularly XYE would flex even under the slightest load. A printer should not be FLEXIBLE especially near the hotend, since all those miniature jumps show up as surface defects on the print. 7. Poor cable management/electronics cooling. The original setup was a spaghetti factory and kept me very limited as to how I could arrange the printer in my workspace since the control box was in a relatively ‘fixed’ position. 8. Poor temperature control. The original hotend would not exceed 260C, which does not work for many of the materials I regularly print with on my other machine (Original Prusa i3 MK3). The heated bed would also take ~45 minutes to get up the temperature I need in order to print (>70C) and refuses to maintain a temperature above 75C without external intervention (heat gun). The shear size of the machine made it very difficult to design a functional enclosure for the machine where I can also gain full control over the ambient temperature and drafts. More problems to list, but these 8 problems drove many of my design choices and if you experience more then half of the problems on this list, or were as severe as my problems, I highly recommend you complete this upgrade. With that being said, this upgrade is not for the faint of heart, it is still a work in progress (meaning files are being updated on a daily basis), there are currently limited – to no instructions (may be completed if enough interest is shown), and this conversion should be done at YOUR OWN RISK. I take no responsibility for any electronic/component/hardware failure. BOM & Preliminary information: Total Print Time: ~1 week Total Filament Used: ~2.5 Kg Total Build Time: ~2 days (almost half of that is calibration/firmware/testing) however you may be able to build it quicker. Tools Needed: Drill and Driver set, Metric Drill Bits, Metric Taps, Metric Socket Set, Wire Strippers Complete List of BOM can be found [here](https://docs.google.com/spreadsheets/d/1rqwowZmV7dKZnKJqoQckv2zRiyOCHZssdogxa7L0-p0/edit?usp=sharing) with vendor, quantity, price etc. I spent a fair amount of time doing research and found these to be the best prices from US sellers (except for a few due to unavailability stateside). After completing many revisions to this project, it has been hard to keep track of what hardware was used (both from original CR-10s5 and purchased), so I apologize for that. Total Cost(s): 200-300 USD [bare minimum, leaving out most upgrades] 700-1000 USD [complete IDEX, enclosure, motors, motherboard, high temperature capabilities, CNC adaptation, etc] These estimates and BOM is supporting US vendors, but I'm sure aliexpress has lower prices on identical items If you would like access to the SOLIDWORK or STP files please email me through hunterbrighton@gmail.com with the desired part(s) or assemblies. I am happy to share my current work if you have something to add on but am still modifying the project daily and do not want to constantly be uploading the new files for the project. PRINT SETTINGS: ***Check complete buildplate STL files to see proper print orientation.*** Every part was printed on my ORIGINAL Prusa i3 MK3 and all parts should fit on a printer with similar print volume. Settings changed part by part, and I am currently assembling a detailed print guide for every part. Here a few basic settings that applied to all mechanical printed parts: No. of walls: minimum 3. No. of top layers: minimum 6. No. of bottom layers: minimum: 6. Infill Density: minimum 31% Infill Pattern: Rectilinear with infill going in the loading direction (meaning you must change the infill direction for different parts). You want the final part to be resemble an isotropic material (quasi is acceptable too) to maximize strength. Layer Height: 0.2mm Nozzle Size: 0.4mm Material(s): ABS, PETG, or HTPLA. Support Material: Some parts, not all. Good luck to you! And I hope the build turns out as well for you as it did for me, as a precaution, the XY-gantry may be completely revised soon, requiring slightly longer belts and different parts. ___ **CrusaXY HB1 Required Maximum Number of Printed Parts** (if a file is not listed but available on thingiverse, determine if you need those parts(s) for your build variation).*If you intend to upgrade to an IDEX version later but want to use the machine in single extrusion mode for some time; you can print and use the IDEX version parts without the additional belts/hardware/ extruder in place, it will just be a ‘bulkier’ build.* **Shared Parts (both IDEX and non-IDEX)** + 2040 support bracket split .….…................................….................…................... qty 18 + 2040 support bracket .….….................................................................................... qty 4 + Zaxis Motor Mount .…..….................................................….................................. qty 2 + 60 tooth Pulley …....…..….................................................….................................. qty 3 + Zaxis Motor Mount Mirrored .….....................................…...................................... qty 1 + Back Right Lower .…..…......................................................................................... qty 1 + Back Right Upper .…..…......................................................................................... qty 1 + Front Right Lower .…..…........................................................................................ qty 1 + Front Right Upper .…..…........................................................................................ qty 1 + Middle Left Lower …..…......................................................................................... qty 1 + Middle Left Upper …..…......................................................................................... qty 1 + Back Lower Pillow Bearing .................................................................................... qty 1 + Front Lower Pillow Bearing .................................................................................... qty 1 + Middle Lower Pillow Bearing .................................................................................. qty 1 + Linear Rod Support ………..................................................................................... qty 2 + Linear Rod Support with endstop ........................................................................... qty 1 + Endstop Mount A ..…..…........................................................................................ qty 1 + Endstop Mount B ..…..…........................................................................................ qty 1 + Motor Mount left side .............................................................................................. qty 1 + Pulley Mount left side ............................................................................................. qty 1 + XY Bracket Left Side .............................................................................................. qty 1 + XY Bracket Right Side ............................................................................................ qty 1 + xy endstop 11mm spacing ...................................................................................... qty 2 + 8.8mm Pulley Spacer ............................................................................................. qty 4 + Teflon 5mm washer .............................................................................................. qty 14 + Main Plate Cover ……............................................................................................ qty 1 + Belt Attachment A .................................................................................................. qty 1 + Belt Attachment B .................................................................................................. qty 1 + Rear Support Plate ................................................................................................. qty 1 + Main Detachable Extruder Mount ........................................................................... qty 1 + Extruder Mount Plate (Prusa version and blank available) .................................... qty 1 **Non-IDEX Parts** + Motor Mount right side ........................................................................................... qty 1 + Pulley Mount right side ........................................................................................... qty 1 + Pulley cover V2 left side ......................................................................................... qty 1 + Pulley cover V2 right side ....................................................................................... qty 1 **IDEX Parts** + Motor Mount IDEX right side .................................................................................. qty 1 + Pulley Mount IDEX right side ................................................................................. qty 1 + Pulley cover IDEX V2 left side ............................................................................... qty 1 + Pulley cover IDEX V2 right side ............................................................................. qty 1 + 15mm Pulley Spacer .............................................................................................. qty 1 + 4.4mm Pulley Spacer ............................................................................................. qty 3 + Rear Support Plate (in addition to previous) .......................................................... qty 1 + IDEX Detachable Extruder Mount .......................................................................... qty 1 + IDEX Belt Attachment ............................................................................................ qty 1 + IDEX Belt Cover (with or without tabs)................................................................... qty 1 + Extruder Mount Plate (Prusa version and blank available) .................................... qty 1