Creality Ender 4 - Linear Rail CoreXY + Belt Driven Dual Z
Description
Introduction ==================== After using the awesome "Creality Ender 4 - CoreXY Conversion" by Greg191134 for a while, I wanted to test linear rails on my Ender-4. This is what I came up with. Benefits ==================== What I observed after finishing this build is, that I can increase the XY jerk setting in the firmware to 35mm/s easily without print quality degradation like ringing.This has the benefit of printing really sharp corners and achieving fast prints on average. While designing this conversion, I made sure to achieve a good rigidiy of the printed parts by using model topology optimization and virtual stress testing, as can be seen in the following figure:  Here you can see the printer in action: <iframe width="560" height="315" src="https://www.youtube.com/embed/MpL7-gAPnVk" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe> Here are some XYZ cube images, with the print outcomes from before the conversion on the left and after the linear rail vonversion on the right.   To verify the circle printing quality, here is a circle print outcome image:  Requirements ==================== This build assumes, that you already converted your Ender to "Creality Ender 4 - CoreXY Conversion". In detail the the motor brackets, the idler brackets and the 20 tooth belt pulleys are necessary for this build. For assembly you will need some - 3 MGN12H 300mm linear rails [link](https://de.aliexpress.com/item/12mm-Linear-Guide-MGN12-L-100-200-300-350-400-450-500-550-600-700-800mm/32861278496.html?spm=a2g0s.9042311.0.0.27424c4dfteSAi) - 12 m3x6 screws - 2 m3x20 screws - 10 m3x10 screws - 4 m3x15 screws - 4 m3x25 screws - 2 m4x20 screws - 4 m5x25 screws - 4 zipties - 5m GT2 belt - E3D V6 hotend - 5015 radial fan (optional) - 8 m3 slot nut After you converted to linear rail, you can reuse the old x-axis extrusion profile for the belt driven dual z conversion.Furthermore you need following parts: - 14 m5x10 - 2 GT2 30 tooth beltwheels [link](https://de.aliexpress.com/item/10pcs-New-GT2-Timing-Pulley-30-36-40-60-Tooth-Wheel-Bore-5mm-8mm-Aluminum-Gear/32822906054.html?spm=a2g0x.search0104.3.1.55866ad1m1JhoV&ws_ab_test=searchweb0_0,searchweb201602_1_10320_10065_10068_10547_319_317_10548_10696_10084_453_454_10083_10618_10304_10307_10820_10821_537_10302_536_10843_10059_10884_10887_100031_10319_321_322_10103,searchweb201603_1,ppcSwitch_0&algo_expid=75490510-418e-49d1-9c74-e65904fd33b1-0&algo_pvid=75490510-418e-49d1-9c74-e65904fd33b1) - 1 closed GT2 belts 784-392T [link](https://de.aliexpress.com/item/SUMRAY-2GT-G-rtel-GT2-616-640-670-696-752-760-784-810-840-848-850mm/32863063742.html?spm=a2g0x.search0104.3.1.763e583eoQdS54&ws_ab_test=searchweb0_0%2Csearchweb201602_1_10065_10068_319_317_10548_10696_10084_453_454_10083_10618_10307_10821_537_10302_536_10059_10884_10887_100031_10319_321_322_10103%2Csearchweb201603_1%2CppcSwitch_0&algo_pvid=f80efd01-2abe-4ea0-90df-41399dba30e3&algo_expid=f80efd01-2abe-4ea0-90df-41399dba30e3-0) - 2 T8 Leadsrews 350mm [link](https://de.aliexpress.com/item/T8-Blei-Schraube-OD-8mm-Pitch-2mm-Blei-2mm-100mm-150mm-200mm-250mm-300mm-330mm-350mm/32918910924.html?spm=a2g0s.9042311.0.0.27424c4d77N4gB) - 1 GT2 pulley 16 tooth [link](https://de.aliexpress.com/item/GT2-Pulley-3D-Drucker-Teile-Zubeh-r-GT2-20-Z-hne-16-Z-hne-16-20/32952582500.html?spm=a2g0x.search0104.3.43.3500f499FXcSRT&ws_ab_test=searchweb0_0%2Csearchweb201602_1_10320_10065_10068_10547_319_317_10548_10696_10084_453_454_10083_10618_10304_10307_10820_10821_537_10302_536_10843_10059_10884_10887_100031_10319_321_322_10103%2Csearchweb201603_1%2CppcSwitch_0&algo_pvid=10478501-1a5d-4f90-9101-4bbb6077e400&algo_expid=10478501-1a5d-4f90-9101-4bbb6077e400-6) - 2 608ZZ skateboard bearings - 14 m5 slot nut - 370mm long 30x20x30x2mm aluminum profile, which is mounted unter the bed to take the front lead screw nut.  If somebody wants to design a printed alternative, I will link it here in the future. Part you need to print for the linear rail conversion: - "xHolder.stl" - "xHolder.stl" but mirrored on one axis in slicer - either "carrierBowdenExtruder.stl" or "carrierDirectExtruder.stl" (support recommended) - "beltWhellHolderLeft.stl" (support recommended) - "beltWhellHolderRight.stl" (support recommended) - "xEndstopHolder.stl" - "xEndstopLimiter.stl" - "yEndstopHolder.stl" - "5015fanNozzle.stl" (support recommended) if you want to utilize a 5015 radial fan. The attachment is designed to allow attachment of [link](https://www.thingiverse.com/thing:2494642) fan shrouts - a 30mm or 40mm fan mount cover from [link](https://www.thingiverse.com/thing:2494642) Part you need to print for the dual Z conversion: - "zAxisRailHolder.stl" - "zAxisRailHolder.stl" but mirrored on one axis in slicer - 2 times "zAxisBearingHolder.stl". There is a ring inside as an inbuild support, which needs to be removed after print. - "zAxisBearingHolder.stl" but mirrored on one axis in slicer - "zAxisBeltTensioner.stl" - "zAxisMotorHolder.stl" Instructions: ==================== Will follow For squaring of the x- and y-axis, I follwed the steps "X Endstop and Rail Adjustment" and "X/Y Belts" from [here](https://docs.google.com/document/d/19FuTYfwqgOkGO8SUScnSuhS_Gx8mJMmXLiPgBfGeJ-s/edit#heading=h.hgyhlizbcumb). Updates: ==================== 01-15-2018: Uploaded working version of the xHolder. The previous version had some screw misalignment.
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