Sovol SV01 compact, lightweight extruder by bartolomeus

Last crawled date: 3 years, 3 months ago

A lightweight and compact extruder setup for the SV01. Completely unnecessary, but a fun project none the less.
The setup is based on the Derpa extruder (https://github.com/wesc23/Derpa-Extruder) and uses a lightweight LDO 36mm stepper motor with integrated 10t pinion. The complete setup (printed parts+bmg+e3dv6+stepper+fans) weighs approximately 270 grams.
Benefits, if any, are:
less weight on x
higher resolution of the extruder (700 steps/mm vs 415 steps/mm)
original bondtech bmg > any clone extruder
original e3d v6 > any clone extruder
unlocks 10mm extra build volume on x (the full 300mm)
Drawbacks:
The small stepper motor can run hot, which seems to be normal. Because of this, it is best to print the stepper mount in ABS.
I never designed layer fan ducts before, so they are sub-optimal designs. Step files are provided.
Not tested with the stock hotend in the BMG. The fan mount will fit, but there might be an issue with the clearance of the fan ducts to the heater block.
Installing requires some tinkering skills: soldering wires, adjusting firmware and stepper motor current.
Some notes:
Before printing parts, read the print settings!
The fan mount fits very tight onto the heatsink. You need some force to snap it into place. There are tabs to use a bolt and srew to tighten it down, but I have not needed those yet. I might remove them altogeher.
This setup will also work with standard NEMA 17 motors. See the last pic. You do not need to print the NEMA14 mount for this.
Parts used:
Original Bondtech BMG
Original E3D V6
LDO 36mm stepper motor with pinion: LDO-36STH17-1004AHG
4010 24v radial fans with ball bearings, gdstime, (2x)
(optional) 4010 24v blower fan with ball bearings (1x)
Installing the 36mm stepper motor:
The 36mm stepper mount mount has an adjustable gear mesh. Take your time to set this correctly. How I did this:
Mount the extruder with the m3x40mm bolts
Mount the LDO stepper motor with the m3x8 bolts
Remove the tension spring setup from the extruder
Move the ldo motor up so the pinion fully engages the bmg spur gear.
Turn the sput gear by hand, and feel the tension on the gears. This is probably too tight.
Now move the LDO motor down a bit untill there is the very slightest play between the gears. Now when you turn the spur gear by hand, you will feel less tension on the spur gear.
Find the optimum spot for the gear mesh by moving the LDO motor up and down.
When you've found the sweet spot, tighten the mx8 bolts. Turn the spurgear again to see if the mesh hasn't changed.
When you're happy, put idler tension setup back on the extruder.
Adjust the Vref on the extruder port of the board. The LDO motor needs 300 - 350mA.
Calibrate e-steps. 703 steps/ mm is a good starting point.
Hardare needed:
Adapter plate:
Reuse stock M5 bolts from stepper mount (2x)
M3 x 12mm bolt
Mounting bondtech extruder:
M3 x 40 mm bolts (3x)
M3 nuts (3x)
Mounting LDO stepper motor:
M3 x 8 bolts (2x)
M3 washers (2x)
4010 radial fans:
M2x ... bolts (8x)