Tronxy X5SA dual gear direct drive

Update 26 May 2023: I was having issues with the filament runout sensor giving me false negatives. I realized tilting the filament sensor slightly resolves the intermittent detection, hence the new part name ending with “slanted”.

Update 24 May 2023: Finally assembled and working. Removed all previous revisions because the cable chain mounting hole pitch is wrong. I have already corrected that in the latest 3D model released. No other changes.

Update 14 Apr 2023: Added filament runout sensor with reverse bowden option, which requires a new version of the extruder mount (V2). Add the other end of the reverse bowden, able to assemble on 2020 extrusion or 4020 extrusion. Still waiting for M4 threaded inserts and realize I need an extension cable for the stepper motor and filament sensor.

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Warning! If you are not reusing the existing stepper motor from Tronxy, take note that the cable from Tronxy does not have the same pinout on both ends and Tronxy's stepper motor might have a different pinout from another manufacturer's stepper motor! Do a small extrude distance to check, if the extruder vibrates and/or does not behave normally, do not proceed! Prolonged running of the stepper motor with incorrect wiring can damage your mainboard!

I found this design https://www.thingiverse.com/thing:3722824 and did some changes:

1. Increased hole size for ease of assembly, 
2. Added threaded insert for cable chain mount.
3. Reduced the thickness of the mounting holes to the original bracket to use the original screws. (Use tree support in your slicer for this area)
4. Added a square hole around the cable chain mounting to allow routing of wires and cable tie point.
5. Added a small C channel to slide the part into the bracket to temporarily hold position while assembling. 
6. Add the option to have a filament runout sensor with reverse bowden on top of the extruder. 

I like the original design concept being able to use most original parts reducing potential complications.

I have kept the mounting hole locations the same while changing the design. I am in the process of getting hold of the parts required and finding time to do this modification. Proceed at your own risk. 

I normally print with 0.2mm layer height, 1.2mm shell (wall and top/bottom), and 20% to 30% cubic infill. 

Parts you will need to complete the build:

• 1x Dual gear direct drive.3mf (3D printed part)(V2 if you want to do reverse bowden) 
• 1x BMG style dual gear extruder
• 1x Stepper motor extension cable (>700mm)
• 2x Threaded brass inserts (M4, OD6, length 5) (min 2, max 4)
• 4x M4x8 screws (length must be ≥ 8mm)(able to use back existing screws 2x M4x6 for though I like longer screws in case I like to add washers and for more thread hold. )

Reverse Bowden option

• 1x Filament sensor reverse bowden.3mf (3D printed part)
• 1x Filament sensor reverse bowden start.3mf (3D printed part)
• 2x Threaded brass inserts (M3, OD 4.5, length 5) (for filament runout sensor)
• 2x Threaded brass inserts (M4, OD 6, length 5)
• 2x M4x8 screws (length must be ≥ 8mm, M4x10 is better)
• 2x M3x16 (length must be >15mm)
• 2x Bowden tube coupler (PC4-01)
• 2x 2020 extrusion T slot M4 nuts (able to use back existing on the filament runout sensor)

Optional

• Filament runout sensor extension cable (>700m) (if you want to move filament runout sensor close to the hotend)
• PTFE tube (ID 3, OD 4) (for smoother reverse bowden, it is also ok to use back existing PTFE tube)
• NEMA17 stepper motor 23mm (slim/pancake stepper motor to reduce print head weight)

Some assembly notes:

1. It is possible to convert to direct drive without disconnecting the cables and disassembling the hotend. 
2. I do not foresee any issues if using the current extruder stepper motor and you can ignore points 3 and 4. 
3. The pancake stepper motor that I listed has a different pinout from Tronxy's stepper motor. I have swapped the pins of the stepper motor extension cable as described in the attached photo and it works. Information source https://www.thingiverse.com/groups/tronxy/forums/general/topic:46528 
4. The pancake stepper motor I used is running at above 80 deg C and I have added a 4010 fan to it (temperature drops to 60+ deg C) while I wait for stepper motor heatsink to arrive. I using this 3D model https://www.thingiverse.com/thing:29572 to mount the fan.
5. I am using velcro straps to secure the extra extension cables. (I am trying to avoid turning this modification into a big undertaking.
6. By using another stepper motor, I will be able to revert back to the original Bowden setup easily if I choose to do so in the future.

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AliExpress affiliate links:

Stepper motor and filament sensor extension cable (need around 1m length extension for X5SA, the limit switch bundled with single axis should be the same as filament sensor)
https://s.click.aliexpress.com/e/_DkG9svr

JST PH2.0 male connector and pins (if you want to modify motor cable ends to create an extension cable, 6pin)
https://s.click.aliexpress.com/e/_Dd43oJb

NEMA17 stepper motor 23mm
https://s.click.aliexpress.com/e/_DE1Xaoh

Generic dual gear extruder
https://s.click.aliexpress.com/e/_DB29mtP

Trianglelab DDB V2.0 extruder
https://s.click.aliexpress.com/e/_DEGgJPj

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