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Section 3.4 Assembling the Extruder

Morris Winkler edited this page Sep 21, 2016 · 17 revisions

Section 5 0019

Finally it is time to build the extruder. The design of the extruder is made to be a dual extruder, but you can also make it a single extruder by leaving out the right hand motor and hotend.


Section 5 0008

Section 1 0017
1x Nema 17

Section 1 0099
1x Filament Pulley

Section 1 0104
1x M3x3 Set Screw

  • Turn the set screw into the filament pulley

  • Fix the filament pulley onto the motor shaft

  • Make sure that:

    • The screw is on the front

    • The screw touches the flat side of the motor shaft

    • !!! The front of the pulley and the motor shaft are not flush ( we got new motors with a longer shaft picture is not updated yet), once the extruder is assembled you can use a piece of filament to adjust the pulley to be in the right position. !!!

  • For a dual extruder, prepare two motors


Section 5 0009

Section 1 0014
1x Extruder Base Plate

Section 1 0049
1x Extruder Fan Holder

Section 1 0020
2x M3x12 Counter Sunk

  • Mount both motors onto the fan holder and base plate

  • Make sure the motors are straight and tighten the screws well


Section 5 0010

Section 1 0100
1x Extruder Center Left

Section 1 0105
1x Extruder Center Right

Section 1 0029
4x M3x20 Screw

  • Make sure the filament path is free. Test it with a piece of filament.

  • Put the plastic parts onto the assembly, but do not tighten the screws yet

  • For single extruder put the right plastic part later, and fix it with the aluminium plate


Section 5 0011

Section 1 0106
2x Extruder Spring

  • Slide the extruder springs behind the plastic part.

  • Push them all the way in, with the aid of the other extruder springs.


Section 5 0012

Section 1 0001
2x 624ZZ Bearing

Section 1 0036
2x 4h8 Dowel

  • Put the dowel through the bearing

  • Place it into the slot hole of the aluminium base plate

  • Repeat for dual extruder


Section 7 0013

Section 1 0106
2x Extruder Spring

  • Slide the remaining two extruder springs behind the heads of the M3x20 screws

  • Tighten the screws (but not too tight!!)

    • The ball bearing is (almost) touching the filament pulley


Section 7 0014

Section 1 0093
1x Radial Fan

Section 1 0092
2x 30mm Fan

Section 1 0035
4x Torx 3 x 16 Screw

  • Click the radial fan into the designated slots of the extruder fanholder part

    • Lead the wire through the cable channel

  • Mount the fans onto the extruder fanholder

    • Make sure the wires for the fans are soldered so the fans are powered with 1 connector

    • Lead the cables through the cable channel


Section 7 0015

Section 1 0098
2x E3D Cooler Body

Section 1 0096
2x E3D Heat Break

Section 1 0097
2x E3D Heater Block

Section 1 0095
2x E3D Nozzle

  • Screw the Heatbreak and the nozzle into the Heater Block

    • Handtight is well enough

    • there might be a teflon inliner , do not put it in yet

  • Screw the cooler body onto the Heatbreak

    • Make it tight, but only hand tight

    • Understand that the heatbreak has a very thin 'neck' which can be damaged with too high force


Section 7 0016

  • Adjust the nozzle in such a way that there is just a couple of tenths of a millimeter between the heater block and the head of the nozzle.

    • The neck of the heat break should be more or less flush with the top of the heater block

    • Everything is fixed, but only hand tight

    • Later the nozzle will be fixed while the hotend is heated to 300°C. This is to make sure the nozzle is press fit to the heat break

    • Fixing the nozzle like this also reduces mechanical load on the heat break while fixing the nozzle


Section 5 0016

Section 1 0094
2x Thermistor

  • Put a piece of heat resistant insulation on both legs of the thermistor

    • Leave about 5mm of blank metal for connection


Section 5 0017

Section 1 0091
2x Heat Cartridge

Section 1 0104
2x M3 Set Screw

  • Slide the heat cartridge into the hole of the heater block

    • The left side of the cartridge should be flush with the heater block

    • Gently fix it with the set screw

    • In a dual set up the cartridges are mirrored. Use the picture of the next step as a reference

  • Slide the thermistor into the little hole

    • Make sure the thermistor is (more or less) in the middle

    • Bend the leads so it cannot slide

    • Bend the leads together so you can connect it later with a connector.


Section 5 0018

Section 1 0015
1x Extruder Front Plate L

Section 1 0016
1x Extruder Front Plate R

Section 1 0021
6x M3x20 Counter Sunk

Section 1 0035
4x Torx 3 x 16 Screw

Section 1 0107
2x FanDuct

  • Put the hotends onto the extruder base plate

  • Connect the thermistors. Polarity is not important

  • Lead the wires through the wire channel

  • Lead the wires of the heat cartridges through the wire channel

  • Fix the hotends with the aluminium front-plates

    • The right hotend can slide some millimeters in it slot.

    • Mount it as far up as possible. The exact height will be adjusted later.

  • Mount the fan duct in front of the hotends with the torx screws

##i3 Berlin
1 Introduction
1.1: History
1.2: Tools and Parts
1.3: Preparing the Casings

2 Assembly of the Y-Unit
2.1: Rods and Power Supply
2.2: Front- and Back- Plate
2.3: Mounting Y-Carriage and Belt

3 Assembly of the XZ-Unit
3.1: Mounting the X-Axis
3.2: Mounting the Z-Axis
3.3: Mounting the Timing Belt
3.4: Assembling the Extruder

4 Wiring
4.1: Wiring the Power Supply
4.2: Wiring the Z-Unit
4.3: Wiring the Y-Unit
4.4: Wiring the X-Axis
4.5: Gluing the Endstop Magnets
4.6: Uploading Firmware
4.7: Wiring the Extruder
4.8: Mounting the Heatbed

Cable Lengths Rumba

5 Calibration
5.1: Testing Functionality
5.2: Calibrating the Y Axis
5.3: Calibrating the X Axis
5.4: Calibrating the Print Platform

6 Printing
6.1: Filament Holder
6.2: Cura
6.3: Kisslicer
6.4: Dual Printing

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