Direct drive extruder for hypercube printers

Inspired by Hypercube Evolution extruder, combined with the power of direct drive extruder and, BL touch and a filament sensor extruder.

To be able to print flxible filaments I needed direct drive extruder, plus i wanted to change my nozzles often. On standard prusha i3 MK3S extruder the process of changing nozzle is a real proccess. I wanted an extruder that makes it as easy as possible.

Features

• Easily maintainable
• Direct drive
• Supports BL touch
• Filament sensor
• Supports E3D Volcano type hotend
• Extruder is exchangable, locking mechanism is compatible with Hypercube Evolution X-Carrige
• Supports Hypercube Evolution Optical sensor homing, but I used it with sensorless homing

Parts

Electronics and movement

• Optical Sensor: https://www.banggood.com/TWO-TREES-10pcs-Optical-Endstop-Light-Control-Limit-Optical-Switch-for-3D-Printer-p-1510313.html
• Prusha extruder gears: https://www.banggood.com/1Set-Prusa-i3-MK2-or-MK3-Cloned-Btech-Dual-Gears-DIY-Steel-Pulley-Kit-For-3D-Printer-Gears-Extrusion-Wheel-Part--p-1382515.html
• Prusha idler spring (any 15mm length, 3mm diameter, sufficiently tight spring will do): https://shop.prusa3d.com/en/spare-parts/599-idler-spring.html
• Turbine Fan 24V: https://www.banggood.com/DC24V-Cooling-Fan-Ultra-Quiet-Turbine-Small-DC-Blower-5015-For-3D-Printer-Circuit-Board-p-1108987.html
• Nema 17 lenght 23mm: https://www.banggood.com/HANPOSE-17HS4223-23mm-Nema-17-Stepper-Motor-42-Motor-42BYGH-0_7A-14N_cm-4-lead-for-3D-Printer-Extruder-J-head-Bowden-Titan-Extruder-p-1437267.html
• BL Touch (I used knockoff for proof of concept): https://www.banggood.com/Geeetech-TL-touch-Auto-Bed-Leveling-Sensor-With-High-Compatibility-For-3D-Printer-p-1154826.html
• E3D Volcano Hotend (I used knock off as a stand in but I designed for volcano), 1.75mm filament, 24V Direct Drive: https://e3d-online.com/products/volcano-hotend

Threaded bras inserts

I used cheap ones from banggood, but like after they pulled out the 2nd time when I was fastening the hotend, I realized, my time is more valuable than what I saved ;D

• Ruthex RX-M3x5.7 threaded inserts: https://www.amazon.co.uk/ruthex%C2%AE-threaded-RX-M3x5-Press-fit-ultrasound/dp/B07YSRGZ9N

Screws

• 1x M3 lenght 40mm
• 2x M3 lenght 30mm
• 1x M3 lenght 25mm
• 1x M3 lenght 15mm
• 2x M3 lenght 12mm
• 2x M3 lenght 10mm
• 4x M3 lenght 8mm
• 2x M3 lenght 6mm

Box of screws I used: https://www.banggood.com/Suleve-M3SS2-M3-442Pcs-Stainless-Steel-Allen-Bolt-Nut-Hex-Socket-Cap-Screw-Assortment-Kit-p-1076216.html

Known issues

• fan and duct do not provide enough cooling for printing with 0.8mm layer height
• optical sensor works unreliably with certain fillaments (especialy reflective PETG)

Optional: Cable connectors

I got MicroFit 3.0 connectors from my local electronics store. You will have to find a supplier near your location.

For the hotend connection I used 12A locking connctor, but i cannot find an international supplier for these

• 3x Molex MicroFit 3.0 Plug 1x2: https://www.molex.com/molex/products/part-detail/crimp_housings/0436400201
• 3x Molex MicroFit 3.0 Receptacle 1x2: https://www.molex.com/molex/products/part-detail/crimp_housings/0436450200
• 1x Molex MicroFit 3.0 Plug 1x3: https://www.molex.com/molex/products/part-detail/crimp_housings/0436400311
• 1x Molex MicroFit 3.0 Receptacle 1x3: https://www.molex.com/molex/products/part-detail/crimp_housings/0436450300
• 1x Molex MicroFit 3.0 Plug 2x2: https://www.molex.com/molex/products/part-detail/crimp_housings/0430200400
• 1x Molex MicroFit 3.0 Receptacle 2x2: https://www.molex.com/molex/products/part-detail/crimp_housings/0430250400

Terminals

Female terminals go into plug housing
Male terminals go into Receptacle housing

• 50x Micro-Fit 3.0 Crimp Terminal, Female: https://www.molex.com/molex/products/part-detail/crimp_terminals/0430300002
• 50x Micro-Fit 3.0 Crimp Terminal, Male https://www.molex.com/molex/products/part-detail/crimp_terminals/0430310002