Flexion Extruder Build Log

So I just placed my order for a Flexion Extruder. This modification seems well worth the money. It is a 1.75mm extruder with a fully guided/supported filament path and a cleaning wheel the cleans the drive gear. What I believe is the most useful function is the idler cam that has 4 preset tensions, 1 being for the most flexible filament and 4 being for the more dense/filled filament. I should be receiving my unit soon and will be posting on this thread updating my development on the project. If you want to read up on it some more the link to the website can be found here: https://flexionextruder.com/

So the Flexion came in today and it looks great! I am so excited to get this going. I will be using the thermistor and heating cartridge from an old hexagon hotend I have this way there isn’t anything to change on the firmware side of things besides the E-Steps. Next thing is for me to get a stepper motor for this and assemble it so I can think of some good mounting strategies. Any tips?

I just finished the main assembly of the Flexion. It is a super simple process and I used the wiring harness, thermistor, and heating cartridge from an old Hexagon hotend. I am waiting for 2 fans and a heatsink to come in. In the meantime I will be designing and printing a mount for this bad boy.

I just found this post and very curious as to the outcome!!! Been wanting to try the dual flexion on my Taz 6. How was the rest of the process, and how are the print results?

Really the Lulzbot Flexystruder just isn’t cutting it for some of my prints. I have lots of prints that require Semiflex/Cheetah and have very thin walls which isn’t conducive for the 0.6mm nozzle.

Any input is greatly appreciated,


This has been put on hold as I have been running my printer 24/7 and can’t afford the down time.

I completely understand. My 1 and only Taz 6 is for business and it runs 24/7 just to keep up with demand. Good luck, and keep us posted if you find time to try out the Flexion.


Here’s an alpha of a TAZ 6 flexion we’re testing.
We’re looking forward to offering 1.75 solid/flex in one tool head!
I’ll share the model once we’ve worked the bugs out- I’m already printing a revision. A Mini version will come after that.

Interesting design. I might have to give the mini version a try when it’s ready.

Updated mount fixes a bunch of issues with the prior design. [edit] 1.75 only. a 1.75 E3D won’t pass 3mm.
Esteps are around 95

Please let me know when this becomes available!!!

I like that mount!

We’re working through how well this will work as a “product” vs. a project.

The extruder body looks to have the bugs worked out, so the .stl is now on Thingiverse http://www.thingiverse.com/thing:1917179

Here’s the onshape project. https://cad.onshape.com/documents/056fe70315481d0aed297645/w/4162b4818bcc4d1af3c99273/e/15addbd24e5a5297f92728f4
As you can see, We’re also working on a version for the Mini, but haven’t achieved a satisfactory extruder arrangement yet

I love my Taz 6, but not too happy with the Flexydually. Really just need more precision, so this seems like a great upgrade. Do you have a list of materials I need to make this, or any kind of build log?

No build log yet, I’ll keep posting here until it’s time for the “product” to get it’s own thread. I’m not yet comfortable that we’ve worked the bugs out, so this is still a “project”

Anyhow here’s what you need to build your own:


Extruder mount http://www.thingiverse.com/thing:1917179
Left fan duct http://devel.lulzbot.com/TAZ/Olive/production_parts/printed_parts/fan_duct_left/
Right fan duct: http://devel.lulzbot.com/TAZ/Olive/production_parts/printed_parts/fan_duct_right/

Now, what did I forgot? :slight_smile:

Thanks so much for posting all of this! What bugs/problems have yall seen with this setup? If they are minor, I might go ahead and start putting this together.

So far, no deal breakers, though attending to sales has sidetracked extensive testing. It’s currently installed on our demo TAZ 5, and I’m “learning” :slight_smile:

  • If you want to print with this dual fan toolhead on a TAZ 5, filament cooling is excessive, just the same as if you swapped to a TAZ 6 V2.1 toolhead. Either stick with a single filament cooling fan, or be prepared for extensive testing to find correct cooling settings. I’m still working on the profile.