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The filament end sensor as installed on the Anycubic i3 Mega S is a bit of a problem. The filament is always pulled from the inner side of the spool which can lead to jumping filament when it comes from the outer side. These cracking noises are worse for the nerves than for functionality but that's still a very good reason for me to look for a change. If the filament would be pulled more from the center it would be much better. That's why I designed a bracket on which the sensor can be mounted away from the portal. To not generate eventual problems on the output side the bracket is 20\u00b0 angled.

The design was done in tinkercad and with its limitations I tried to keep it simple. I use tinkercad because it is the only program my wife is happy with and I want to be able to answer questions in case she has some.

Installing it is a bit tricky as a new M3x10-12mm screw has to be inserted inside the \"printed tube\" and tightened thru one of the mounting holes for the sensor. Then the sensor has to be installed with the original and a new M3 screw and two M3 nuts.

Printer settings: Resolution 0.3mm with adaptive layers. Infill doesn't matter with the thin walls I simply left the standard fill. Support is best from everywhere and as the contact area is pretty small I also printed with 5mm brim.

Since I have the sensor installed that way I never had this nerve racking noise generated and the sensor didn't unscrew itself either.

A more detailed project report with step-by-step explanations in German language can be found here: https://www.die-heimwerker.net/t692f22940-Verlagerung-des-Filament-Endsensors.html . Google translate should take care of it for other languages.
Even though it is a German language newsgroup don't hesitate to ask in English there in case you have questions.

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