Ender3 direct extruder modification

thingiverse

2020-07-20 4) another correction. 4) two M3x5mm hex wrench bolts >> 4) two M3x20mm hex wrench bolts. Added "10) M3x16mm button head hex socket or plus screw bolts" missed from the first requirement description. Additional clarification on the description and note. Additional comment on printing and correction(M3 & M4 taps >> M2 & M3 taps) 2020-07-17 correction to the 3) requirements in 2020-07-16 description: "four M3x30mm wrench bolts" is revised to "four M3x40mm wrench bolts" 2020-07-16 uploading a newly updated direct extruder for Creality Ender3 incorporating Bondtech clone with 17Ncm NEMA17 stepper motor to reduce weight of the DDE. I have printed many ABS parts for extended time that takes about almost a day with no particular problem. In an enclosed chamber, the ambient temperature goes up to 50 deg Celsius where I found occasional loss of torque. Hence better to maintain the chamber below 45 deg. My cheap cooling motors show fast degradation over multiple 24 hours ABS prints. I am wondering if more expensive cooling motors would survive under this harsh condition. Overall integration requires a bit of tinkering. Requirements: 1) NEMA17 18Ncm stepper motor. 1.6"x1.6"x0.8" (42x42x20mm) 2) Aluminum cooler for the stepper motor (refer to the photos) 3) four M3x40mm hex socket screw bolts for fixing the stepper motor and the extruder to the mounting bracket 4) two M3x20mm hex socket screw bolts (to fix the aluminium cooler to the stepper motor at the two top screw hole replacing original motor screws) 5) four M3x10mm hex socket screw bolts for the fan cover 6) four M2 bolts reused from the stock blower fans fixing the two print cooling blower fans 7) two 40x10 "blower" fans (the stock print blower fan can be re-used), 24V 0.1A 8) one 40x20 "blower" fan, 24V 0.1A 9) one >40mm M3 screw bolt for hot end cable mounting pole if tightened vertically 10) M3x16mm button head hex socket or plus screw bolts Note: need to drill a M3 hole to make a vertical cable holder, 9) above, with some protective cover around the thread of the bolt to avoid cable damage from. Use at least two cable ties to fix cables on the hot end fan cover holder while the PET expandable braided sleeve fully squeezed on both ends to make the cabling steeper. The 40x20 blower fan is slotted in with two screw bolts(M3x16mm button head screw bolts) at the top position which are then permanently screwed inside the slot via two holes provided on the mounting bracket. When you fix the two 40x10 print cooling blower fans, do not over tighten the M2 screws as they will deform the fans due to the shape of the fan on the mounting holes. The heater and the thermistor cables must be positioned inside the fan mounting bracket. The hot end silicon cover can be placed at the end. The print cooling air outlet holes should be shaped with a cutter to 45 degree angle as "/" on the left and \ on the right to direct the cooling air to prints.