A1 Extruder Front Cover - Skeleton Frame Mod

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A1 EXTRUDER FRONT COVER - SKELETON FRAME MOD

⚠️READ BEFORE PRINTING⚠️

Unlike most of my A1 models, this mod is NOT purely cosmetic. Whilst it was designed purely as a drop-in replacement, this mod could affect the performance of your extruder assembly if installed incorrectly, or installed with defects such as warping or part shrinkage. If you have performed a deep clean of your extruder gear before, this mod will not be difficult for you, but please read the description and take all suggestions into consideration when deciding to print, install and use this modification.

 

Lastly, I am not responsible for any damage or abnormal wear that could be a result of installing, using, mis-installing or mis-using this mod. Please treat your devices with the care and love they deserve.  
 

I designed this model to replace the original, screw-fastened front cover to the extruder assembly on my A1. I purchased an aftermarket, metal extruder gear as a more durable component prone to less wear. But it's quite a pretty gear, and I want to be able to see it, so I reverse-engineered the cover and made a skeleton frame of it, only keeping critical geometry similar to a skeletonized mechanical watch. It's aesthetically pleasing, gives insight to how the extruder mechanism looks, and opens way for easier & less intrusive maintenance!

Consider printing the A1 Skeletonized Faceplate to pair with this mod!

Please follow the steps and suggestions below to ensure a successful installation:

 

Download the .3mf file associated with the model. It contains custom support settings critical for dimensional accuracy. If using a different slicer, please consider these support settings:

After the part finishes printing, wait for it to completely cool before removing from the build plate and carefully remove the supports. Ensure all interface material is removed from the stair stepped tab in the back, as this geometry is used to properly locate the Filament Sensor Base when installing. Please also ensure that the port for the filament cutter is free of any stringing or additional support material.

When removing the support from the countersinks, I use the ends of the allen keys that came with the A1 to pop them out. It requires moderate force, but will break free like a small piece of candy.

Follow the Bambu Lab Wiki guide for A1 Series Extruder Cleaning Tutorial up to “Step 4” to remove the Extruder Front Cover. From here, you may continue the tutorial to clean your extruder gear since you're already here.

Before installing the new Extruder Front Cover, test fit the Filament Sensor Base in the new Extruder Front Cover. The fit should be snug, but easy to fit in place. After confirming the Filament Sensor Base fits, proceed to the “Assembly Instructions” of the wiki tutorial. If you did not continue with cleaning your gear, you may pick up at “Step 3”

After “Step 6” of the Assembly Instructions, push the Filament Cutter to verify clearance for the cutting tool. You should be able to push the lever inward, and have the lever retract on it's own with no assistance. If not, uninstall the Extruder Front Cover and examine the cutter port. Confirm there is no support material or stringing that occurred within this port, and remove any if there is. If you have cleared this port and still find jamming issues with this cover, DO NOT USE THIS COVER. Reinstall the old cover, and feel free to leave a comment or contact me directly for assistance with troubleshooting.

At the end of “Step 7”, you can use the same screws from the old cover to tap the holes on the new cover. After installing the Pressure Block, verify once more that there is clearance for the Filament Cutter.

Once the Extruder Front Cover is installed, you may bask in it's skeletal glory, or you may consider printing the skeleton faceplate that goes with it next:

Like accessorising your A1 with colour? Consider some of my other A1 customisation models!

A1 Z-Axis Cap Covers

A1 Z-Axis Pillar Covers

A1 Z-Axis Crossbeam Cover

A1 Hats

A1 Print Base Front Cover

 

Thank you to the following creators whose models inspired this mod!

 

Ian Holing - A different take on an open cover mod

thanhson.thanhquyt - Another interesting take on a minimalist cover mod

Riky2141 - Honourable mention for also coming up with a similar concept earlier than I did

 

Printed and tested with Bambu Labs PLA Basic