Announcing A New Belted extremely compact Extruder - The Nova Pro

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piercet
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Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by piercet » Sat Jan 14, 2017 2:29 am

I've been working on this as a side project off and on for a little while now. I've always been interested in belt driven extruders, because they theoretically have more responsive retraction than a geared design. I also wanted something that had as absolutly as short a distance between the hobbed things to the hotend as possible, used a Bondtech dual drive hob core, had an easy to access idler. and was stiffer on the mount than other designs. And thus, this extruder was born.

Presenting, the Alpha revision of the Nova Pro Belted Precision Extruder! (lots of pictures, files further down along with more details)

Project repository: http://www.thingiverse.com/thing:2036899
IMG_2600.JPG
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Last edited by piercet on Sat Jan 14, 2017 2:50 am, edited 1 time in total.

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piercet
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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by piercet » Sat Jan 14, 2017 2:32 am

Here are the build files:

There will eventually be a left hand and a right hand variant of this extruder body, to allow for a more compact dual extruder. There is also going to be a lower fan shroud. For now you can use the stock E3D V6 fan. Also this presently fits an E3DV6 and requires a circular 6mm thick Mounting flange, several M3 bolts, an 8mm bondtech extruder core (roughly $85 shipped in from Sweden), belts, pulleys and M3 bolts. Also an M8 bolt and some washers. A full parts list, sources, etc. will be posted once its finished.
Attachments
NovaPro_Tensioner_2_1_a.stl
(43.05 KiB) Downloaded 62 times
NovaPro_Taz_mount_rh_1_0_a.stl
(712.48 KiB) Downloaded 57 times
NovaPro_Idler_Latch_1_2_a.stl
(184.46 KiB) Downloaded 63 times
NovaPro_Idler_Half_2_RH_1_0_a.stl
(73.32 KiB) Downloaded 64 times
NovaPro_Idler_Half_1_RH_1_0_a.stl
(59.75 KiB) Downloaded 65 times
NovaPro_Extruder_Body_RH_1_0_a.stl
(585.04 KiB) Downloaded 59 times

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piercet
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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by piercet » Sat Jan 14, 2017 2:34 am

More pictures:
IMG_2584.JPG
IMG_2585.JPG
IMG_2587.JPG
IMG_2590.JPG
IMG_2592.JPG
IMG_2593.JPG
This extruder is officially hereby licensed under Creative Commons - Atribution. Other format files are available upon request, I just don't like generating them if no one is going to use them.

Sebastian
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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by Sebastian » Sat Jan 14, 2017 8:51 am

I noticed that there is a bigger diameter section just below the hobbed gears. Do you plan to insert a short piece of PTFE tube there?
How do you change the filament with this system, is it necessary to unscrew the two screws completely?

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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by piercet » Sat Jan 14, 2017 11:25 am

The lower filament hole should be the same diameter as the upper at the moment. I've debated putting the PTFE in there, it's a short enough run I don't know that it would do anything positive to the feed path though. I can certainly make a variant that allows for it.

To load filament, you just slide the latch up, flip the idler down, and then remove the old filament. if there is no filament loaded already, you cana ctually just load it by sticking the fiillament in from the top and hitting advance on the extruder too.

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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by piercet » Tue Jan 17, 2017 1:29 am

Lower duct parts now exist. also more pictures:
IMG_2601.JPG
IMG_2602.JPG
IMG_2603.JPG
IMG_2604.JPG
IMG_2605.JPG
IMG_2606.JPG

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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by piercet » Tue Jan 17, 2017 1:33 am

Files:


I'm not sure I'm 100% done with the outer fan ducts yet, but the center turned out great. The new mount plate is required to fit the ducting, though if you already printed the old one you can just cut the ends off of it, as that is the only change. I'll also be making a large pile of "nameplate" ID tags for the extruder body in the next few days to tell multiple extruders apart. Examples "E3Dv6 0.5mm" or "extruder 1, 2, 3" or "Extruder A, B, C" etc. If you have a naming scheme you like to use, please let me know what it is and i'll make sure to add it.
Attachments
NovaPro_Taz_mount_rh_1_1_a.stl
(696.86 KiB) Downloaded 67 times
NovaPro_RL_Duct_2_7_c.stl
(660.63 KiB) Downloaded 72 times
Novapro_ID_E3Dv6_5.stl
(458.48 KiB) Downloaded 68 times
Novapro_ID_Blank.stl
(16.78 KiB) Downloaded 67 times
NovaPro_Center_Duct_back_1_0_a.stl
(468.15 KiB) Downloaded 73 times
NovaPro_Center_Duct_1_0_a.stl
(441.2 KiB) Downloaded 68 times

alexmit
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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by alexmit » Tue Jan 17, 2017 1:15 pm

Have you tested flexible materials through it yet? It would seem this would work well with either rigid or the most flexible filaments.

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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by piercet » Tue Jan 17, 2017 3:28 pm

It seems to feed great so far. I haven't finished wiring the hotend yet to test it further than that. but in terms of constraint path and travel distance, it should feed even better than my dedicated flexible filament model. The only difference is this one lacks the PTFE tube, but for such a short distance I don't think it will even be noticed as missing.

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Re: Announcing A New Belted extremely compact Extruder - The Nova Pro

Post by piercet » Sun Feb 12, 2017 4:38 am

I finally had a chance to get back on this project. Here is revision 2.0 of the main extruder body. I'll need to adjust the mount to fit the changes I made as well, so this will not fit the 1.0 mount, it will leave a gap. Look for the new mount to go with it tomorrow, along with a few for several other printers.

This latest version eliminates the 608zz bearings and replaces them with two smaller ones, a 12mm dia unit in the front, and a 15mm dia unit at the rear. That allows me to make the entire extruder 2mm thinner, eliminate about 1/8th the plastic around the bearing housing itself, use a shorter bolt, and cut the bearing weight down to 1/2 of 1 608zz bearing down from 2 of them. I may still be able to get a bit more plastic weight down by making the upper segment shorter, but the upper mount point has to be above the rear pulley so there is very little material I can remove there anyways.

I'm pretty happy with how it looks, we'll see if it prints as well. if it does and everything lines up, this will probably be the variant I issue the left hand version of for use with dual extruder setups
novapro2_1.png
novapro2_1.png (11.14 KiB) Viewed 2672 times
novapro2_2.png
novapro2_2.png (9.27 KiB) Viewed 2672 times
Attachments
NovaPro_Extruder_Body_RH_2_0_a.stl
(472.84 KiB) Downloaded 60 times

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