DIY Filament Motion Sensor

DIY Filament Motion Sensor.

Designed this motion sensor using some parts laying around.

A compact design with dimensions of 49x39x30mm.

Filament has little drag applied to it so the extruder does not have to apply torque to pull and there's an opening to check that the wheel is spinning.

Sensor type to be like that pictured.

Currently working on Klipper config settings and will upload these settings once I have it working. No Marlin support sorry.

BOM:

4 M3x30 FHCS bolts

4 M3x5mm brass inserts

2 M2.5x10mm STCS (self tapping hex head screws)

1 M5x40mm Knurled Axel/Pin

2 HK0509 5x9x9mm Metal Needle Roller Bearing

1 MR85ZZ 5x8x2.5mm ball bearing

1 Optical Switch Limit/Endstop (3 wires)

5mmØ ball point pen spring, cut to 6-8mm length. The longer the springer the more tension.

Print Settings...

I made all the interlocking projections of the Top.stl solid, where the 2/M2.5mm screws screw in... need that area to be reasonably strong. When screwing in the screws do not force them as I found the projections may break off, then it may not fit together.

I recommend a well tuned and calibrated printer for parts to fit as intended otherwise a resin printer.

STL's in PLA+ or ABS+

Top/Base @ 0.2mm layer height with 4 walls, 4 top and bottom layers with 30% grid infill.

Sensor Wheel @ 0.16mm layer height with 1 wall and solid fill. Fill all gaps on.

Tensioner @ 0.16mm layer height with 1 wall and solid fill. Fill all gaps on.

TPU Wheel @ 0.24mm layer height with 2 walls with 3 top and bottom layers and 30% grid infill.

My heated bed temp set at 65-70°C.

Critical parts...

Sensor https://www.aliexpress.com/item/1005003078185312.html?spm=2114.13010708.0.0.64a34c4dOq3GyS

Bearings https://www.aliexpress.com/item/33026400709.html?spm=2114.13010708.0.0.64a34c4dOq3GyS

https://www.aliexpress.com/item/32862242083.html?spm=a2g0o.productlist.0.0.6ad9441arlZQNv&algo_pvid=7f04be4c-689e-4c70-9d97-bcb94fc2cba5&algo_exp_id=7f04be4c-689e-4c70-9d97-bcb94fc2cba5-3&pdp_ext_f=%7B%22sku_id%22%3A%2212000018027692216%22%7D&pdp_pi=-1%3B2.95%3B-1%3B-1%40salePrice%3BNZD%3Bsearch-mainSearch

Knurled Axel/Pin https://www.aliexpress.com/item/1005003445969306.html?spm=2114.13010708.0.0.64a34c4dOq3GyS

Works for me.

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