Tornado/MK3S Bondtech Geared Extruder-Direct Drive, BLTouch, Filament Sensor

thingiverse

This is a remix of the Bondtech Geared "Prusa I3 MK2.5S / MK3S Extruder upgrade" to work on a linear rail and the stock FlyingBear Tornado (Gen 1) steel carriage plate. https://www.bondtech.se/en/product/prusa-i3-mk3s-extruder-upgrade/ The original upgrade kit uses the following: - E3D v6 hotend - 25mm NEMA 17 pancake stepper motor (direct drive) - inductive bed leveling sensor - optical filament runout sensor - part and heatsink cooling fans I have modified this to attach to the carriage plate mounting screws on the Tornado, and allowing space for the carriage plate-carriage hex heads that stick out. In addition, I have removed the inductive bed leveling sensor and switched it to a BLTouch as most of us use glass beds. If you can afford it, I do recommend buying the gears and parts from Bondtech, as they took the time to develop these excellent designs. Their build quality is also top-notch. [upgrade kit](https://www.bondtech.se/en/product/prusa-i3-mk3s-extruder-upgrade/), [gears only](https://spool3d.ca/bondtech-drivegear-kit/) However, you can also purchase from TriangleLabs this [upgrade kit (option 1)]( https://www.aliexpress.com/item/32998931899.html?spm=a2g0o.productlist.0.0.387d22aeSsUNRB&algo_pvid=6b2b0699-fae8-46ed-8d99-ef61d3e3ff06&algo_expid=6b2b0699-fae8-46ed-8d99-ef61d3e3ff06-0&btsid=0ab6f83915874206077021155e76c3&ws_ab_test=searchweb0_0,searchweb201602_,searchweb201603_) and [gears](https://www.aliexpress.com/item/32947193804.html?spm=2114.12010615.8148356.1.62c4b571l4Ro49) Note that the Tornado V1 is a 24V system. The stock MKS Gen L board supplies 24V for both part and hotend cooling fans, so you will need either 24V fans or a buck step-down converter to use 12V/5V fans. Fans are 5015 centrifugal/blower, and 4010 cooling. Prusa recommends printing with black PETG (CF-PETG is likely even better), 0.2mm layer heights, 30% GRID infill. You will likely need a ~0.4mm or smaller nozzle. You can use other colours for many of the parts, but black is recommended for parts surrounding the optical filament runout sensor. ABS is recommended for part cooling fan shroud. If you use the extruder files w/built-in supports, you can print without adding any additional supports in slicing software. I have successfully printed in PETG; note that depending on your printer, you may need to drill out/dremel holes and tight tolerances. This also printed very well using a Formlabs SLA printer. Fan shroud is the model by RH_Dreambox, the shroud support has been modified. [Regular/V6](https://www.thingiverse.com/thing:4376765) [Mosquito](https://www.thingiverse.com/thing:4217188) Note that you will have to switch out/add some of the hardware including but not limited to: - 3x M3x10 bolts with nuts for BLTouch - Bottom left (looking from the linear rail side) M3 socket cap screw for attaching to the carriage plate requires ~M3x30 instead of M3x40, top left requires additional M3x10 or M3x12 bolt and square/regular nut. - This will also require a few press-in M3 inserts and square/regular nuts. - The reverse-bowden sensor cover (if you choose this option) uses a PC4-M6 fitting. SLA version has holes for brass M3 threaded inserts widened, as you cannot install these using a soldering iron as with FDM plastics. Instead, install with some cyanoacrylate. The filament runout sensor needs to be modified as not to interfere with the carriage plate when plugging in the connector. You need to desolder the right-angle pin connector on the sensor and resolder it from the opposite side of the board. The sensor cover and extruder rear piece have been modified to fit this already. This is a work in progress. I would appreciate all feedback in the comments section. Original files from [Bondtech Github](https://github.com/BondtechAB/Bondtech_Prusa_i3/tree/master/CAD-Files) *Changelog:* Update (2020/09/17): Corrected X-carriage mounting plate holes, added BLTouch mount with additional surface for X-endstop, corrected fan shroud mounting and support, added SLA version with larger brass thread insert holes Update (2020/04/26): Added reverse bowden/filament guide version of sensor cover. Update (2020/04/25): After test prints, reinforced thin walls in E3D version near heatblock. Added ziptie mounts on rear, removed ziptie mounts from BLTouch_Mount. Added STL files with custom supports. Update (2020/04/22): Further optimized for printing. Updated summary. Fixed filament sensor cover and extruder rear for vertical filament sensor connector. Slight improvement to the extruder_front to allow more bolt length variation in the top right mounting screw. Improvement to BLTouch mount and extruder_rear for cable management. Update (2020/04/21): Modified to make it easier to print using FDM (removed honeycomb on back), remixed to add an option to use a Mosquito hotend. Originally posted (2020/04/21)