Remote Direct Extruder with Dual drive gear-set

thingiverse

**Hi everyone! Let me present you my latest design, a remote direct extruder which uses the dual drive bondtech style gear-set, as I like to call it "Remote BMG".** **Check the second improved version here:** https://www.thingiverse.com/thing:4048275 For those unfamiliar with remote direct extruder - its basically a direct extruder for which the gear-set is driven remotely via a flexible steel drive-cable. The extruder motor is mounted on the frame of the 3D Printer. Therefore this design have the benefits from both direct and bowden extruder systems. I started first with direct extruders then in the hope of reducing the ringing effect I switched to bowden extruder and got tired of so many troubles with coupling failures uncontrollable friction in the bowden tube, too much elasticity, and so on...those printing with high speeds + high extruder acceleration knows what I'm talking about :). So I was thinking it's time to change and try a totally different approach like a direct remote extruder. Form the first results I have to admit it works better than I have expected. **Key Features of the design:** - Dual bondtech style drive gear - really high grip; - Extremely high torque due to the high gear reduction ratio; - Weight about 40 grams (with carbon fiber gear shaft); - Could easily print up to 250mm/s - Designed for 1.75mm filament **Link to the design Fusion360 online 3D viewer:** [RemoteExtruder](https://a360.co/2OXl6i9) [Extruder MotorMount](https://a360.co/2R3Vqmq) Print testing between 50-250 mm/s: https://youtu.be/4bbcH8Qa4JU - result look pretty decent. Tried also 300mm/s where slight under-extrusion was visible at the print areas where the printer actually reached that speed. Printing with 150mm/sec: https://youtu.be/7qfuxtMpvR4 Extruder stepper in action @150mm/s printing speed: https://youtu.be/83xA3AYlX5c Attached ripple test-cube was printed @70mm/sec. Check out also the printer which is able to go that fast: https://www.thingiverse.com/thing:3509583 **Bill of materials:** - 1x [Dual drive mini gear-set](https://www.aliexpress.com/item/32947193804.html?spm=2114.12010612.8148356.55.710c55b4m3sIhO) - 1pcs [Mini bearings MR148-ZZ 8*14*4mm](https://www.aliexpress.com/item/32863047313.html?spm=a2g0s.9042311.0.0.27424c4dAiYjCG) - 3pcs [Mini bearings MR95-ZZ 5x9x3mm](https://www.aliexpress.com/item/32861184011.html?spm=2114.12010612.8148356.29.65c82170j5LTjX) - [5mm carbon fiber rod](https://www.aliexpress.com/item/4000038397236.html?spm=a2g0o.productlist.0.0.6dda674fH4Zses&algo_pvid=26ece7b6-690a-4ed7-ba51-a82a92b99b4d&algo_expid=26ece7b6-690a-4ed7-ba51-a82a92b99b4d-8&btsid=16076a0e-88ea-4a3a-8567-fee31ee853f1&ws_ab_test=searchweb0_0,searchweb201602_9,searchweb201603_55) - 2pcs [6mm PFTE coupling](https://www.aliexpress.com/item/32851457478.html?spm=a2g0s.9042311.0.0.27424c4dxkpb7k) - 1m [6mm PFTE tube](https://www.aliexpress.com/item/32990119021.html?spm=a2g0s.9042311.0.0.27424c4dOjajvh) -1x [Thumbscrew assembly](https://www.aliexpress.com/item/32947691813.html?spm=2114.12010612.8148356.31.710c55b4m3sIhO) -1x [3-5mm shaft coupling](https://www.aliexpress.com/item/33004890424.html?spm=a2g0s.9042311.0.0.27424c4dAiYjCG) - 3pcs [M3 insert nut 4mm lenght](https://www.aliexpress.com/item/33004890424.html?spm=a2g0s.9042311.0.0.27424c4dAiYjCG) - M3 screws 1x22mm; 1x25mm; 1x30mm - 1pcs full metal V6 heatbreak (optional for the metal filament guide) - 1 pcs [Embedded Bowden Coupling](https://www.aliexpress.com/item/32893940934.html?spm=a2g0s.9042311.0.0.27424c4dDIh5XJ) - optional for the PFTE filament load guide **Flexible driveshaft:** [3mm flexible drive shaft](https://www.aliexpress.com/item/33003100366.html?spm=a2g0s.9042311.0.0.1a7c4c4dMPRJ4G) I have tested this design on my [MachCube2.0](https://www.thingiverse.com/thing:3509583) I have used a NEMA17 pancake stepper motor from a clone titan extruder. **Duet Wifi** electronics with the following **settings for the 10:1 gear ratio** - (further refinement is still needed): - 1412 steps/mm using 16x micro-stepping - Acceleration: 600 mm/s^2 - Maximum instantaneous speed change: 200 mm/min - Maximum speed 1000 mm/min - Motor current 800 mA - pressure advance 0.1s - Retraction 2mm - Retraction acceleration 80mm/s Print settings: - The worm gear-set and the 6mm bowden shaft couplers housing must be printed at maximum 0.1 mm layer height (I sued 0.4mm npzzle with 0.1mm layer height) - print material is PETG (waiting for the IGUS filament) - the gear-set must be as perfect as possible and must be lubrified. - The body of the extruder shall be printed max 0.15mm layer height. - For a better accuracy print the split worm gear-set and glue them together afterwards; I have designed two types of gear-set one with 10:1 and second with 30:1 gear ratio. If you printer is not able to print very fast due to its mechanical construction limitation you may use the gear-set with 30:1 gear ratio. Of course acceleration and jerk settings must be reduced by a factor of 3 and increase the number of step/mm by factor of 3. **PS** This design is still under work, lots of further testing still needs to be done, design will suffer further updates. **I welcome every constructive feedback and suggestions to further improve the design.**