Ender 3 Ultralight Modular Mount for Orbiter Direct Drive with E3D v6, NF Crazy, and Mosquito Hotends
Description
*These designs will only work for linear rail carriages which are more compact as the bottom wheel and plate will get in the way of the fan for the stock carriage. I added a single nozzle part cooling fan for the v6 hotend model to work around this for those using the stock roller carriage.* **Updates** * V5 - Single Nozzle part cooling fan added for stock x carriages V4 - Updated BLTouch mounts and redesigned wire routing V3 - The design is now modular to support the v6, mosquito, and nfcrazy hotends. Each hotend has an altered part cooling fan and bltouch mount and the hotend can be changed out with only a few screws. V2 - New fan design with dual part cooling nozzles and an increase in bltouch offset to prevent knocking V1 - Simple one sided fan duct for v6 hotend only* This is my own design to fit the orbiter direct drive extruder to an ender 3 with multiple hotend designs capable of high temperature printing. It is very rigid and lightweight for minimal inertia, vibration, and backlash. It incorporates a 3015 or 4010 fan duct for the v6 hotend as well as a 5015 fan and duct for part cooling. Overall weight is dependent on the hotend. Less than 300g with a Mosquito or NF Crazy and less than 350g with a v6. Everything but the heatsink fan duct can be printed in PLA because they will not get hot. I recommend printing the heatsink fan ducts in PETG or nylon because they are semi flexible and will withstand high hotend temperature. Print in the orientation shown with supports on build plate only. I support anything over 60 degrees on mine but you may need as low as 45 depending on your printer's capabilities. The fan duct is designed to be glued on. This allows for the easiest printing orientation, reduces weight and minimizes vibrations. I recommend hot glue, rubber cement, or elmers glue in that order as they are not permanent but will give good hold and prevent vibration. Parts all have fairly tight tolerances in order to maximize rigidity (most importantly the mount for the v6 heatsink). I recommend using horizontal expansion (cura) or xy compensation (slicer/prusaslicer) setting of -0.04. 0.2 layer height with .4 nozzle. I recommend 4 walls with 25% zigzag/rectilinear infill and 5 bottom/6 top layers. Assembly requires assorted M3 bolts, brass nut inserts, and a couple nuts. Links to the parts I used: iExcell 525 Pcs M3 x... https://www.amazon.com/dp/B08P2J3QQX?ref=ppx_pop_mob_ap_share iplusmile Brass Nuts Embedment... https://www.amazon.com/dp/B087NBYF65?ref=ppx_pop_mob_ap_share For wire routing, I ran my fan wires along the top of the heat sink and behind the bltouch up to the wire groove. The hotend and bltouch wires are run from the back up into the groove as well. there are small indentations at the top of the wire support guide to secure a small zip tie to keep all the wires in place. I recommend using an extra 2 feet of PTFE tube or a thick solid wire to add to the group of wires to give it a solid backbone and reduce bending, then wrap it all in a cable sheath/wire loom. My Bltouch offsets in Marlin are approximately { 32, -1.6, -1.76 } but you will have to slightly alter your Z offset to account for different nozzles. Silent fans I recommend for the v6 hotend: 3015: http://www.mouser.com/ProductDetail/sunon/mf30151v2-1000u-a99/?qs=EU6FO9ffTwdnE%2fGnxTNt2w%3d%3d&countrycode=US¤cycode=USD I don't recommend the 3015 fan for prints much over 240C as you may experience clogs due to less heatsink cooling. I've got many successful and quiet days of printing with it in PLA though. Also it is 12V so a buck converter is required for 24V machines. 4020: Sunon Vapo bearing MF40202V2-1000U-A99 4020 fans are overall much better than 4010 fans as they can produce higher cfm at lower noise levels with minimal added weight. Part cooling: Just about any 5015 blower fan will work, I don't focus on noise as much because it's easy enough to adjust part cooling flow with PWM/print settings. ***Caution: The basic one sided fan duct for the 5015 blower may cause overcooling on one side of prints if set to 100%. I recommend 60% or less. The two sided duct will be sufficient in most cases at 90% or less. A note of caution - I have found that the housing and mounting holes of the orbiter extruder vary between some designs and some manufacturers as well as from version to version. I can only ensure that it works with the part from Printed Solid (v1.5) because that is where I bought mine from, completely assembled. If you find yours is different, you will have to edit from the design file based on your own measurements. Or make your housing using the thing linked below. Please post or send me changes if you make them so that we can make this available for all the variations. Orbiter purchase link: https://www.printedsolid.com/products/ldo-orbiter-v1-5-140g-dual-drive-direct-extruder?variant=32974481227861 Thingiverse design file link: https://www.thingiverse.com/thing:4725897 STL files are all organized in a zip folder to make things easier and parts are arranged per their respective hotend. Please share your builds, like and comment. Happy to answer questions or update parts. I will post the project or step files from fusion 360 soon for those who wish to edit for a different version of the orbiter or different touch sensors and fans. Also be on the lookout for an ender 3 mount for the mosquito hotend and a dual extruder mount for the mosquito and v6 coming soon.
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