I realize these pics aren’t the best, but it’s the best I can do right now.
The new heater is noticeably longer than the one that came with my Reprapdiscount setup. Would be nice if the new heater was the same length, so it didn’t hang out so much.
This shot will give you an idea how much the heater sticks out. Don’t get your fingers in there!
The angle makes it look like the Reprapdiscount version is noticeably longer, but they are about the same length. The big differences are that the there are fewer heating fins on the new version and the heat block is bigger. Also there is a plate that screws on the right side now to hold the cartridge and thermistor in place.
Here is a picture of my custom ‘Fangtooth’ setup. The big differences here are the fan that comes with it that is more similar to the E3D V6 fan/shroud setup, except the shroud is 3d printed. The mini blower fan on the Taz Hexagon is a pretty neat alternative.
If I had to speculate I would think that the new version has a larger heat block to increase the size of the melt zone and decrease extrusion pressure. The shorter cooling area is probably as a result of wanting to increase the size of the heater block, but not wanting to add any additional height to the extruder. I would love to see a blog post wink
from Lulzbot talking about the new hot-end and why they made the changes over the original hexagon.
Regardless of the difference, they both have worked well for me and I’m very happy with both of them. Either is a decent upgrade over the Buda to me.