The Copernico Extruder

I wanted to try a large gear extruder for my Trident and - while Galieo 2 may have been the easy choice - I did not want to buy another Galileo set, especially since the new version is completely incompatible with the old one I have (yes I may be a little salty about that). I did find a very interesting project from user nhchiu however due to the space occupied by the two large gears adding two filament sensors is very difficult and is not compatible with most toolhead boards. Therefore, I decided to design my own extruder. The design is inspired by the Galileo 2 extruder (hence the name) but it is lighter (only about 10g over the standard clockwork 2) and much cheaper since it uses HGX lite gears. Specifically, it uses a single HGX gear plus a bearing to avoid gear alignment problems (see MirageC video for details). It is compatible with the sb2209 family of toolhead boards and possibly all other toolheads since the space available for it is slightly larger than the space available in a standard clockwork 2 extruder. It also natively supports 2 filament sensors and the FilamATrix filament cutter system (you need the short arm for clockwork 2).

This is only a beta version and may be subjected to changes, if you want to try it and give me some feedback I will appreciate it a lot. I will provide the step file once the design is finalized.

BOM:
1     HGX lite gear set 
1     NEMA 14 36mm round stepper motor
1     MR148 bearing (14x8x4 mm)
1     4x24 mm steel pin
1    ECAS 4mm fitting
2    5.5 mm steel bearing
2    D2FC microswitch
5    M2x10 SHCS    (4 for the microswitch and 1 for the board support)
1     M3x6 SHCS     (for fixing the toolhead board)
1     M3x8 SHCS     (for connecting the extruder to the X carriage or tap)
2     M3x10 SHCS   (1 for connecting extruder back to the motor 1 for the toolhead board)
1     M3x12 SHCS    (screw gearbox front and back together)
2     M3x20 SHCS   (1 for the main body through the bearing and 1 for the electronic cover)
3     M3x25 SHCS   (1 between the gearbox to the motor and 2 for the main body)
1     M3x30 SHCS   (for connecting the extruder to the carriage through the main body)
1     M3x35 SHCS   (for the tension spring)
2     M3x8 BHCS     (1 for the cable retainer and 1 for closing the electronics cover)
2     M3x6 FHCS     (for connecting main body back to the support arm)
11     M3x4 insert     (2 supporting arm, 1 gearbox back, 5 main body back, 3 main body front)

All parts should be printed in ABS using Voron standard printing guidelines, with no supports needed. 

First add all heat inserts in the 4 parts that require them. Then build the gearbox without installing the motor yet. Attach the supporting arm to the rear main body using the two FHCS screws (you will not be able to access them once the gearbox is in place). The gearbox is then installed in the rear main body and fixed in place with the long screw that tensions the sping. You can now attach the motor to the gearbox (adjust the spacing as you would in the CW2). Add the electronic cover using one of the two M3x20 screws. Install the bearing on the rear body and the two filament sensors in the front part of the body. You can now connect the two parts of the body with 2 M3x25 (one at the top and one at the bottom) and the remaining M3x20 in the centre. The board support is held in place by one M2x10 screw.

Detailed build guide soon.