QED Hot End Cooling System with Convergence Part Cooling Nozzle for: Creality CR10 CR10S Pro V2 Ender3 Ender5 MicroSwiss E3DV6 Volcano Hotend 4010 5015 Direct Drive

Quod Erat Demonstrandum
"What was to be shown"

INTRODUCTION
I designed a cooling system that is easy to use.

I wanted to upgrade my machine to allow for visibility and access to the hot end without taking anything off. I wanted to be able to adjust my part cooling duct wherever I wanted not just where somebody else thinks it should go and I wanted to be able to upgrade to direct drive if I ever find myself printing flexibles.

It is super easy to service the hot end, it is easy to see the part printing. I can adjust the part cooling while it prints and it is capable of adjusting from a standard 10mm heater block all the way up to a 50mm super volcano. I set mine with a 2mm allen wrench under the nozzle.

I put a large effort into equally distributing and focusing the part cooling duct(PCD)/nozzle but even with all my design intent I was surprised that with a 4010 blower it performed almost as well as my benchmark tests with 5015 dual fan cooling systems. When I upgraded to a 5015 fan it exceeded them without causing any PID faults, concerns or variations between 100% fan and completely removed while using a silicone sock.

I decided to give ABS a second try, it never worked with my old setups, even with an enclosure...and it was REALLY REALLY easy to print. So easy that I now prefer to print ABS because it is more predictable then PLA. The ABS parts stick to the glass bed way easier than PLA parts ever did and they don't pull up in the corners, or split, or anything. (I spray hair gel on the glass). What I have been able to deduce is that my design eliminates the possibility of drafts generated by the heat sink cooling fan ever reaching the bed. Further testing showed that only a slight amount of air deflected from the heat sink fan onto the bed would curl prints away from the glass.

COMPATIBILITY
This is just a short outline highlighting some basics. I created a.pdf document that gets into the details including selection, settings, assembly and usage recommendations. This design is intended to be intuitive but there are a few methods that can inhibit the functionality of the system. Some components may not print to dimension with the wrong resolution, others can be damaged by improper use and some may fail to print with the wrong fan configuration.

Verification key:
●Models with confirmed assembly to actual components.
¤Models confirmed by mounting to a printed .stl file. (Thigiverse or mfr sourced)
○Designed to be compatible based on various resources but not explicitly certified. This includes interfaces generally assumed to be the same such as the x-carriages for the cr10, mini and Ender 3 which are generally accepted to be the same component but because I don't have all these machines I can't certify fit. If you successfully install on one of these options please post a make with your machine model.

Here is a quick breakdown of available x-carriage interfaces.
CR10 - Post mounted carriage with a zero offset and mounting holes or slots for as many carriages as I could find.
CRV2 - Flat carriage based on the CR-10 V2.
MSDD - Microswiss DD specific.

I included designs for the E3d-V6, Creality's Pro as well as the rectangular Mk8 and Micro Swiss Hot ends. The MK8 and MS are very easy to use and perform excellently in heat sink temperature dissipation. The E3D-V6 design performs almost as well in preliminary testing but is awkward (personal preference I guess). The Pro was verified with a "make".

Hot end compatibility with each interface type.
CR10》 ●mk8, ●MS (CR10), ○MS(Pro/Max), ●E3d-V6, ●Pro/Max
CRV2》 ●E3d-V6, ●MK8, ●MS(CR10), ○MS(Pro/Max)
MSDD》 ●Mk8, ●MS(CR10)

For the traditional 2 post Creality carriage layouts I made a template for checking the bolt pattern against yours. It is only a few layers thick so it is a quick print and will tell you if the holes line up. You don't even need those extra bolts with the zero offset if you are using a post mounted hot end without DD.

Here is a list of machines that should work with corresponding HSR interface.
● CR10 Mini 》 CR10
○ CR10 》 CR10
○ CR10s 》 CR10
○ CR10s Pro 》 CR10
○ CR10s Pro V2 》CR10
○ CR10S4 》 CR10
○ CR10S5 》 CR10
○ CR10Max 》 CR10
○ CR20 》 CR10
● Tevo Tornado》 CR10

● Ender 3 》 CR10
○ Ender 3 Pro 》 CR10
○ Ender 3 V2 》 CR10

¤ Ender 5 》 CR10♧◇

¤ CR10 V2 》 CRV2
● CR10 V3 》 CRV2

¿ CRX 》 maybe ¿CR10? It utilizes a hotend based off the "Pro" design and looks to have a similar carriage but I haven't found any dimensions.

¤ MicroSwiss DD CR10》 MSDD♤
○ Microswiss DD Ender 5》 MSDD♤◇♧
○ Microswiss DD CR10 LR》 MSDD
○ Microswiss DD Ender 5 LR》MSDD◇♧

♧ Requires the use of a specific PCD for standard and volcano hotends. No PCD is currently designed to work on this machine with a super volcano.

♤The lower wheel mounting tab interferes with the placement of the part cooling duct and as such, when using a wheeled version, the 263° cooling ducts are only compatible if using a volcano hotend. There are no current PCD designs compatible with the 10mm heater block. (Mounted to an .stl model of the CR10 V-wheel version)
All standard heater blocks should be compatible with linear rail versions.

◇This has a feature to clear the left belt end on the OEM Ender 5 Carriage.

AUTO BED LEVELING
I made mounts for ABL including BL touch and all the proximity sensors which incorporate both EZABL sensors. The size ranges roughly correlate to the height of the heater block. The offsets are absolute and on the physical parts.

DIRECT DRIVE
I made modular direct drive mounts that replace the strain relief for common extruders. I verified the OEM but have not mounted them with the others. Based on center of mass considerations direct drive extruders that pass the filament to the left of the stepper motor shaft when viewed looking down the shaft will balance better and impart fewer cantilevered loads into the system. The exception being the V2 design which specifically preserves the OEM configuration to mount a stepper motor in front of the carriage and is only compatible with paths on the right of the shaft.

● OEM(Plastic)
○ Titan
○ natiT
○ Pro dual / Winsinn
● Bondtech BMG left and right

BED LIGHT
I also made provisions for a bed light. It mounts onto the part cooling duct or the optional mount. It is super simple, made up of the arm and the light bar. There are extra components in case you want to get creative with where you put the light. There are several lengths of light bar but you can easily stretch the length in a slicer to obtain exactly what you need. It is attached with a single M3 screw so it is also easy to design and utilize a customized bar with your preferred retension features.

FAN ADAPTERS
There is a fan adapter for use with most popular fans. The Heat Sink Retainer and the Part Cooling Duct with lateral fan ports are capable of accepting a wide variety of fan sizes.

● 4010 R
○ 4020 R
● 5015 R
○ 5020 R

I even included adapters for axial fans. If you are considering the use of one please read the discussion in the documentation as they are ill suited for this application. Alternately you can watch one of these videos to get a better understanding of how fans perform.
Basic fan type overview.
https://m.youtube.com/watch?v=0CUWf34JKFI

Experiments with ducts and directed airflow.
https://m.youtube.com/watch?v=SX-okOHvh1Q

● 4010 A
● 4020 A
○ 3010 A

COMPONENT SELECTION / INQUIRIES
For questions regarding testing, design and component selection please review the .pdf file first. It contains a design overview, testing results and detailed descriptions of each component as well as fasteners and processing instructions to help you determine which components will suit your needs and how best to install them.

I will not be releasing solid or source models for core components.

PRINT ORIENTATION
I DO NOT CONTROL THE DEFAULT ORIENTATION OF THE 3D PART PREVIEWS. They have no relation to how I designed parts to be printed. If you are wondering why there are only a few previews it is because back in 2020 when this was loaded the site was glitchy and the only way to reorder pictures to get the cover photo in place was to delete everything that came up in front of it which included the entire preview library. I haven't been able to find a way to re-generate the previews so only revisions and additions have previews.

For most parts I assume that the orientation is intuitive and leave it to the user.

If I posted a slicer image it is to show a peculiar aspect or orientation of the slicing based on how I developed the part. Ultimately it doesn't matter but if you are having difficulties this might be why.

*Hint: I tend to put a point (teardrop) on the top of horizontal holes in vertical surfaces so the hole doesn't get effectively squished while printing. I do not put them on vertical holes I intended to go through the top or bottom surfaces.

MATERIAL CHOICE
I'm adding a clarification about material choice here as it's easier to update than the pdf. In the reference documentation I make several warnings about how the choice of material will effect how resilient your assembly will be and warn that using low temperature plastics can lead to warped parts. I will clarify.

• summary: if you print anything other than PLA, print this out of a better material because elevated temps will deform it just like they will defirm anything else you print with PLA and u use around heat. I'm just a bit over analytical and feel compelled to share all results.
  -Every component can be made from relatively low temperature plastics such as PLA.
  -The difficulties arise if you then print in an enclosure. The PLA PCD and HSR will warp and distort.
  -PLA PCDs are also more likely to distort if you print a large first layer and accidently set part cooling to zero instead of low (5-10%) because there is absolutely no down draft incidental cooling from the heat sink cooling fan. In fact this scenario can also distort higher temperature plastic PCDs. Keep in mind this scenario also applies to time spent waiting for the bed to heat up with a preheated hot end.
• my experience: I've had PLA HSRs look like potato chips after printing in an enclosure set up for printing ABS. I've had ABS and PLA PCDs warp the nozzle outlets when I've run them too long with the part fan off. It is cumulative. The nozzle can slowly curl up with the more time operated with the part fan off. This it's why I recommend ABS or PETg because it is more forgiving over the long term but PLA will work great if you are diligent with your settings.

REVISIONS
2021.03.14 Updated PCD.263.5015.zx to clear the ferrule on Ender5 belt.
2021.03.12
-Renamed HSR CRZed to CR10 with removal of offset variants.
-Revised all HSR CR10 designs to accommodate the Ender5 left belt.
-Added HSR CR10 20x35, Pro
-Shifted HSR CRV2 E3d-V6 closer to the factory nozzle position.
-Added HSR CRV2 20x30 & 20x35.
-Added PCD 263.5015.zx
-CRV2 test fit to model https://www.thingiverse.com/thing:4610356 by WilliamKEddy
-Ender5 test fit to model https://www.thingiverse.com/thing:3694056 by LoCoCNC
2021.03.09 prep for revisions. HSR CR8 obsolete and removed.
2021.02.27 Added HSR MSDD Rect20x30. Due to interference with the wheel mounting tab, the PCD is not compatible with wheeled versions using shorter than volcano heater blocks but should be fully compatible with all standard heater blocks when using a linear rail version.
2021.01.31 Added a layout template to transfer mounting plate holes to facilitate geometry capture of new interfaces. Optimized for mk8 mounting posts. In both .stl and .step to allow for quick printing and confirmation of geometry.
2020.12.17: Added Prototype HSR for CR10V2/V3 with an E3d-V6 style hotend. Due to the compact height of this HSR, DD configurations that pass the filament to the left of the stepper motor shaft are not compatible.