AeroXtruder NX

Project Description

If you have a Titan Aero clone printer, would like a new extruder with a large gear to feed the filament, and don't want to spend $100 or more on a new extruder, then this project is for you.

Benefits of the new AeroXtruder NX drive for Titan Aero
- Low cost (it is a fraction of the price of a new extruder),
- Once modified, the new drive fits into the space of the original drive, the X axis does not need to be mechanically modified, there is no need to recalculate the new distances of the Z probe axis from the nozzle axis, only the software changes to accommodate the new drive gears,
- The new drive uses the original Nema 17 motor.
- We get a drive with a large gear that feeds the HGXlite filament,
- uses an ingenious pressure lever, modelled on the @Prusa3d Nextruder, which increases the contact surface between the feed wheel and the filament,
- You can seamlessly revert to the original version if you have problems installing the new gear.

This is a specific design for the Titan Aero heat sink manufactured by Artillery.
Different Chinese versions of the Titan Aero may have a heatsink of a different size and shape, but the mounting system for the NEMA 17 motor is the same.
If you have another printer with a Titan Aero Extruder then nothing is lost, you can buy the original Artillery heat sink and mount the whole thing in your printer in place of your Titan Aero Extruder.

This is my original idea for a new extruder drive to replace the TitanAero gear clone. I used the experience gained from remixing the excellent ProtoXtruder by @nhchiu, also with the @Prusa3d Nextruder lever.

To visualise the finished AeroXtruder NX in the Artillery Sidewinder X2 warhead, I used the model from: 

https://grabcad.com/library/artillery3d-sidewinder-x2-extruder-and-x-axis-carriage-1
 

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To build the AeroXtruder NX you will need:

1. Artillery SidewinderX2 or GeniusPro extruder or at least an Artillery heat sink(affiliate link).
2. HGX lite kit (affiliate link)- kit parts needed for AeroXtruderNX:
- 3mm shaft (16mm length) x 1pcs to be converted into 2pcs 3x7.5mm
- 3mm shaft (24mm length) x 1pcs
   Instead of the original 3x24 shaft from the HGX kit, I recommend the following 
   cylindrical steel pin DIN 6325 3x25 mm m6 cut to 23mm
- large filament gear with pin bearing x 1pcs
- heat inserts (M3 x D4.5 x H5) x 4pcs (one trimmed to M3 x D4.5 x H4.5)
- M3x8mm BHCS x 1pcs
- M3x12mm BHCS x 1pcs
- M3x14mm SHCS x 1pcs trimmed to M3x10mm

3. Trianglelab TBG-lite Reduction Gear with shaft x1pcs and bearing x2pcs.

I bought mine on aliexpress - unfortunately they are no longer available there.
Trianglelab replied to me that this would no longer be available.

I found a link to another platform (it is not an affiliate link) but have not used it and cannot confirm that everything is OK there.

4. Trianglelab brass gear 5mm/0.5M 17T (affiliate link) or other similar 5mm/0.5M17T(affiliate link).

5. Other parts needed for extruder and lever system: 

- M3x6mm SHCS x 1pcs
- M3x20mm SHCS x 2pcs
- M3x7.5mm FHSCS x 1pcs
- M3x16mm FHSCS x 1pcs
- M3x26.5mm FHSCS x 1pcs
- M3x32mm FHSCS x 1pcs
- M3 nut x 1pcs
- Tubular spacer 4x3x8.9mm x 1pcs - I made one out of a brass tube that I have(affiliate link)

- shaft 3x7.5mm x 2pcs (I cut a free pin 3x16 from the HGX gearbox)
- 683ZZ bearings with U-groove x 2pcs (affiliate link)
- M3x20mm BHCS x 2pcs
- M3 nyloc nut x 2pcs
- spacer 6x3.1x8mm x 1pcs (affiliate link)

- M3x45mm SHCS x 2pcs trimmed to M3x31.5mm
- Spring 5x15x0.8mm x 2pcs - I made two from the long one I bought earlier(affiliate link)

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 Klipper/Marlin settings.

Klipper:
[extruder]
rotation_distance: 56.55  # rotation_distance needs to be adjusted
gear_ratio: 45:17, 37:16

The clipper itself changed my thread feed direction (there is an extra gear) to the correct direction.

Marlin:
Two values need to be changed in the "Configuration.h" file and then the new firmware compiled:

1. You need to change the direction of rotation:

#define INVERT_E0_DIR false

Change to

#define INVERT_E0_DIR true

2. You need to change the number of steps per millimetre:

#define DEFAULT_AXIS_STEPS_PER_UNIT { 80, 80, 400, 445 }

Change to

#define DEFAULT_AXIS_STEPS_PER_UNIT { 80, 80, 400, 370 }

I have given the value of steps per millimetre as theoretical - you should adjust it for your own printer by sending the appropriate g-code using, for example, Proterface.

If you cannot compile new firmware for your printer, you can change the value of steps per millimetre directly with g-code via Proterface.

The direction of rotation of the motor can be changed by dappropriately switching the pins on the motor plug.

But you will have to find a tutorial on how to do this yourself.

As I recommend compiling new firmware and updating this in the printer.

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Print settings.

Print parts from ABS/ASA.
You can print from PETG (I haven't tested) if you don't have a built-in printer, but I recommend printing them from ABS/ASA.

Nozzle 0.4, layer 0.2, infill 40%, 4 perimeters.

The design considers a print with a layer height of 0.2mm.

However, in order for the parts to fit correctly, the back, front of the case (BACK and FRONT) and both halves of the lever arm (idlerAlever, idlerBlever) have the highest surfaces in multiples other than 0.2mm.

Therefore:
- idler Lever A and idler Lever B should be printed on a separate printout with the 'Precise Z Height' option enabled and:

layer height 0.2
first layer height 0.2

- The BACK should be printed on a separate print with the 'Precise Z Height' option enabled  and:

layer height 0.2
first layer height 0.2

- The FRONT should be printed on a separate print with the 'Precise Z Height' option enabled  and:

layer height 0.2
first layer height 0.2

THE FRONT, in addition to the supports I built into the model, must have hand-painted supports in the area shown in the photo below.

After cutting in the slicer, it should look like this:

If you have never printed precision parts for a printer I will add a tutorial (pdf) and *.3mf files.

After printing.

After printing the “idlerLeverB”  the integral support (the grey part in the photo) must be carefully removed:

When assembled, the idlerleverB must not rub against the gear teeth of the filament:

After printing the “FRONT”  the integral support (the grey part in the photo) must be carefully removed:

!!!!!!!!!!!!!!!!!!!!!!!!!!!

An important step before assembling the AeroXtruder NX:
When assembled, the TGB reduction gear teeth lock against the 3x23mm filament gear axle:

The axle of the 3x23mm filament gear has to be slightly reworked (at a certain distance it has to be reduced in diameter to about 2.5mm so that the teeth of the TGB reduction gear do not block against it:

Dimensions for the reworked 3x23mm shaft:

The photos below show my 3x23mm shaft conversion looking after installation in the BACK section.

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Assembly.

I have added tips and assembly instructions in a pdf file (manual under preparation).

For the assembly of the lever system I recommend the original @Prusa3D manual, but keep in mind that in my version some of the dimensions of the parts may differ.

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Note:

For lever assembly, you can refer to the Nextruder lever assembly instructions on the Prusa website:

https://help.prusa3d.com/guide/5-nextruder-assembly_434014

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Assumptions according to which I designed the AeroXtruderNX:

• low cost,
• the new drive must fit into the space of the original drive so that the X-axis does not need to be mechanically modified, only the software will change to account for the new drive gears,
• it must use the original Nema 17 motor,
• large HGXlite filament feeding gear,
• pressure lever modeled on the @Prusa3d Nextruder,
• trouble-free return to the original version in case of problems with the installation of the new gearbox.

NOTES.

• The design is my idea to modify an extruder for my printer.
• This is not a certified solution dedicated to the Artillery Sidewinder X2 compliant with VDE, IEC or similar standards.
• Any modification to the printer done by yourself increases the risk of accident and fire.
• Never leave the printer on unattended.
• Use at your own risk.

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Updated 27.03.2025
I have added full assembly instructions.

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Updated 25.02.2025
Updated description.

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Updated 07.02.2025
Updated description.

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Updated 01.02.2025
Updated description.

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Updated 30.01.2025
Updated description.

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Updated 26.01.2025
I have added new version: 

AeroXtruderNX_FRONT_v3.stl 

AeroXtruderNX_idlerLeverA_v1

AeroXtruderNX_idlerLeverB_v1

The built-in supports have been changed to make them easier to remove.
Plus cosmetic changes to make installation easier.

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Updated 21.01.2025
I have added new version: AeroXtruderNX_FRONT_v2.stl 

and *.3mf files

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Updated 16.01.2025
I have added preliminary (not full) assembly instructions and print tips.

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Updated 15.01.2025
Updated description.

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Updated 13.01.2025
Updated description.