Abandoned!!! Nova 3D Printer - An Ender 5 inspired printer

EDIT 2022-01-28: After working on this for quite some time, I've decided to abandon this project. There were quite a number of design flaws that I had not considered. I have instead disassembled my Nova printer and used the components to build a Voron 1.8 instead.

Nova: A custom 3D printer inspired by the fantastic Creality Ender 5

My Ender 3 suffers from a number of small issues. After digging into it a bit to find solutions, I found that I can fix these issues by simply installing a handful of new parts, but then it turned out that the total of the new parts I needed would be about 50% of the price of building a new 3D printer, so I decided to do that instead.

The objective here wasn't perfect quality, speed or anything of the sort. I simply wanted:

• A bigger print volume
• Fewer issues than what I had with the Ender 3
• Higher quality components (EG: SKR board vs Creality, TMC2209 vs 2208, etc...)

Some key differences between the Nova and the Ender 5 include:

• Larger build volume (310mm x 310mm x 350mm)
• TMC2209 stepper drivers
• 0.9 degree stepper motors
• External MOSFET modules
• SKR 1.4 Turbo mainboard

For more details, please refer to my GitHub repository:
https://github.com/billgeek/nova-custom-3dprinter

BOM

Here is a link for the bill of materials for this printer:
https://docs.google.com/spreadsheets/d/1B5keSqVwSLgc5OjsFatlqAnYNtMWsLssTLB85XMptbM/edit?usp=sharing

In total I spent just shy of CAD $720 on all the components.

Printed Parts

The bill of materials linked above includes the list of parts and quantities:

• LeadScrewNutHolder x 2
• LowerAngleBracket x 4
• UpperAngleBracket x 4
• XAxisGantryPlate x 1
• XMotorBracket x 1
• YAxisCover x 2
• YMotorBracket x 1
• ZAxisPlate x 4
• ZMotorBracket x 2

All parts were printed in PETG at 60% infill and at 0.28mm layer height.