Solar Orbiter (Ender 3/pro/v2) ( Bowden/Orbiter Extruder & Dragon/V6/DragonFly BMS/Stock hotend & optional BLtouch mount ) by squirrelf

Last crawled date: 3 years ago

Latest update:

version 0.9: small tweak on the part cooling exhaust, to help air go toward extruded filament.


new fan cover 3mm thick


version 0.8, lowered and extended fang output, closer to filament, and increased tunneling duct volume to reach the left "fang", balancing air better. tested with stock and dragon, there still space below

Since ender 3 and pro can't simply use a metal bltouch mounting system, I added a BLTOUCH version for all ender 3 (3/pro/v2) and also a bowden+bltouch (smooth top, no orbiter mount), (if you have an ender3v2 metal bracket, keep using it)
(X offset -43)
with stock hotend Y offset should be -8
with dragon/v6 hotend Y offset is 0
with dragonfly BMS hotend Y offset should be -8 + washer size used, so probably -7.5 with a 0.5mm washer
Material needed:
X Grantry mount:
Three m3x8
Orbiter:
Two m3 nuts
Two m3x12
dragon / v6 only:
Three m3x8
Two m2.5x8 ( use extra screws that came with the dragon )
front fan:
m3x30 max length with a 40x20fan (or 40x10fan plus fan cover/grill)
side fan:
m3x20 max length (m3x30 if you use a 40x20mm fan)
NEED TESTER
Still untested compatibility with ender 3/pro needs someone to test it. (don't even have to print it all just a few layers to see if holes line up), it should be compatible just need confirmation.
Unknown compatibility with other v6 style, only dragon was tested.
—-
Some random but important order of install:
can be printed without support, minimal cleanup needed (only one small problematic area that can be cleaned easily)
remove X gantry completely if installing dragon/V6 type hotend
tighten top right x gantry wheel before attaching the dragon/v6 holder
remember to slide in m3 nuts in the two back channels before mounting, those will attach to the orbiter (use m3x8 screws to secure the orbiter), once you have the nut in place, maybe put temporary screws to keep them in place
attach Bowden tubing before mounting the duct, you will need to precut it before (length will depend on your hotend, just make sure it slides in the orbiter completely)
route bltouch cable during mounting the duct, but before placing any screws
route front fan cable before securing orbiter
with official bltouch metal bracket, and dragon hotend, offset X is still 43mm (should be with all hotend), Y is now 0 (or close enough to zero that zero should be a good value)
UPDATE HISTORY
(April 7, 2021) version 0.9:
small tweak on the part cooling exhaust, to help air go toward extruded filament.
added a non orbiter version meant for bowden without bltouch printed mount.
(April 7, 2021) version 0.8:
extended and lowered the part cooling output a bit to blow even closer to the extracted filament.
increased volume of the tunneling duct connecting to the left fang to help with air flow.
added a dragon bltouch version
tested a print with no support, and results are great, very little cleaning needed.
(April 6, 2021) version 0.7 + BLtouch:
Same as previous version, with printed Bltouch mount (X offset = -43mm)
Another version dedicated for Bowden with Bltouch (no orbiter mount)
(march 31, 2021) version 0.7:
to avoid support inside the side fan area, I added a couple "wings" to act as support without affecting air flow. Haven't tested it, so I'm also leaving version 0.6 for now, until someone tells me that it is good, I'm not panning on printing it since version 0.6 is what I have now and works great after some clean up.
So only support needed with 0.7 would be the cable routing for the side fan, or print without support and just clean that up afterwards.
Added a 10mm thick fan cover to slide in and sit flush in case you use a 40x10mm fan on the front.
(march 28, 2021) version 0.6:
One of the gantry mount hole was off, from a past mistake after rebuilding my X gantry in fusion, forgot one vertical measurement, if you already printed it, use a solder iron to move the small top left mounting hole down my about 1mm.
Added step file of a base model without side fan for customization.
It's installed (initial release version) and printing great my machine. Going to print version 0.5 of the duct with the new dragon hotend.
Turns out the dragon nozzle is 1mm lower than stock on my design ( according to my new z offset )
(march 27, 2021) version 0.5:
changed the air duct splitter, for a roughly better 50/50 air ratio (hopefully still works without support)
quality of life improvement, added little dips where the m3 nuts (to attach orbiter) slides in at the stock/dragonfly level, and another at the dragon level. so that should help them stay in place, and made a larger opening, as the hole opening was a bit smaller, from minor elephant foot issue during print.
added hole for ender 3 mount (untested, need someone to test that for me)
added vents on the left side, hope that's enough for ender 3 since it doesn't have a back hole in the gantry
(march 27, 2021) version 0.4:
added more clearance for left screw head that attaches to the left rail wheel
(march 27, 2021) version 0.3:
small oversight regarding bltouch cable guide, the connector would not be able to fit, so I enlarged a hole so that the connector can slide sideways
(march 27, 2021) version 0.2:
left side mounting holes increased to 3mm diameter
tested: V6 style mount works perfectly on real X gantry (small correction in description, I thought the hot end mount were m2.5, they are actually m3, so use m3x8, original screws are too long. but use m2.5x8 to attach the V6 mount to each other, I used the one that came with the dragon)
Original Post:
This design originally started for my Ender 3v2 with the Orbiter Extruder (though if you like the design you can use it in a boden setup of course). I soon after bought a dragon hotend so I worked on it to accommodate it (and at the same time other hotend).
You will find a mounting system for v6 style to attach the dragon to the X gantry, use m2.5x8 that came with the dragon to attache the two pieces together, and m3x8 for the 3 screws that attaches to the X gantry.
This took me many days (weeks) to built and 3 versions built from scratch.
If you like what I do and want to support me, donation are very appreciated.
Print with gantry side facing down
Universal version - optional print support (detail below)
dragon
dragonfly BMS - fit test in CAD
dragonfly BMO - didn't test fit in CAD
E3D V6 and clones - didn't test fit in CAD
Dragon version - optional print support (detail below)
dragon
may or may not be compatible with other v6 style mount - E3D v6 or dragonfly BMO
Dragon Mount - no print support
print 1of2 with grantry side on the print bed, inner half circle facing up
print 2of2 with nose down, inner half circle facing up
Regarding print support:
I designed everything I could that had overhangs with arches to reduce overhang print issue to a minimum.
only needed part is side fan cable channel, has overhang that will need cleaning up if you don't use support, but not being a crucial part, or use prusa slicer and paint custom support right there.
Second less important area is the curved overhang inside the side part fan, might not be super pretty, but should be easy to clean it enough to not be an issue, and hidden behind fan anyway, otherwise paint a few dots of support
flat overhang directly next to the side fan, should be a non issue. not perfect but functionally usable without cleaning up, otherwise print support there for a cleaner look.
Other notes:
rotated the dragon hotend 180 degree, so the long part of the heat block is facing the gantry to avoid being too close to the PLA (non issue with dragonfly BMS, don't know about dragonfly BMS)
fan screw holes are m3, with 10mm depth holes so you can use m3x25->m3x30, and m3x15->m3x20mm for side fan. holes are tapered so that screw catches on better.
dragon mount uses screws that came with the dragon to attache the two pieces together (m2.5x8) For grantry mount original screws are too long, use m3x8 instead, and another m3x8 for the back of the X gantry.
measure and use a small cut piece of boden tub between hotend and orbiter.
I print everything with gyroid infill, 10%-15% should be plenty.
printed at 0.24mm
cable guide for bltouch, add before mounting
screw in top right rail wheel compactly before installing the dragon/v6 hot end
if attaching the orbiter after mounting, remember to slide m3 bolds in the guides, as they are only accessible form the back
I printed in PLA, haven't had issues with previously printed hotend duct, we shall see if this holds true with this one. PTEG/ABS is obviously safer.