LeapFrog Creatr Extruder Modifications for NinjaFlex Rubber Filament

thingiverse

Most extruders won't print flexible filaments like NinjaFlex and you need to modify the drive mechanism before you can print. The creatr's extruder is basically a modified MK8 extruder, but most of the spring loaded extruders on thingiverse won't fit a Creatr or they don't properly contain flexible filament. I worked with engineers from NinjaFlex to modify my Creatr with a spring loaded extruder drive mechanism and it works awesome. Printer settings: Speed: 30 mm/s Temperature: 220C See instructions tab for details Enjoy! 8/9/2014 - added step file for the whole assembly per user request Instructions Print the following parts if you have a single extruder: 1) Pin 2) Arm 3) Base Plate Print the following parts if you have a dual extruder 1) Pin (2) 2) Arm 3) Base Plate 4) Mirrored Arm 5) Mirrored Base Plate Remove the front plate and fans from your extruder assembly. Then remove your Motor with the two screws located on the cold end bar at the bottom of the motor. Also removed the fixed bearing plate and spacer plate behind it. Remove the drive gear pulley and replace with a 1.75mm filament pulley (see below where to order). The drive pulley that comes with the creatr is designed for 3mm and won't squeeze the filament enough to properly drive it into the extruder. You need to file/sand/drill the printed parts to make sure they fit and slide together. My prints required the hole on the base plate to be drilled out so the pin could spin freely. Be careful to not drill all the way through the parts. I also had to file down the cut out for the drive gear pulley so it could spin without dragging on pulley. Make sure you don't remove the bump that is located in the center of the pulley hobbled area. This is critical for keeping the filament from being sucked into the plastic part and jamming the extruder. The arm needs to be tapped with an M4 thread to accept the bearing screw. I also had to drill out the Arm to make clearance for the bearing screw head. Try to make this hole tight around the screw head. Reassembly the extruder with the new printed parts. The spacer plate and fixed bearing plate are not needed, but you need to remove the bearing, washers, and screw to install them on the arm. Remember to replace the drive gear pulley with a new one for 1.75mm filament. You need to buy the following parts: 1) Spring: McMaster Carr 9657K306http://www.mcmaster.com/#9657k306/=ru23qy 2) 1.75mm drive gear pulley: Ultibotshttp://www.ultibots.com/micro-extruder-drive-gear-1-75mm-filament/ I also recommend checking out Ninjaflex's site for tips on printing:http://www.fennerdrives.com/default.aspx?node=ninjaflexfaq&