modular x-carriage (prusa i3, prusa mk3)

This is a modular x-carriage, which can be used for both direct drive and bowden setups.

All parts can be printed without supports and are assembled using M3 screws and nuts.

M3 screws:

2x 25mm (belt holder)

12x 25mm (bearings)

4x 10mm (bowden hotend mount)

1x 10mm (fan clamp)

1x 20mm (fan clamp)

1x 10mm (fan duct)

2x 30mm (20mm hotend fan)

2x 10mm (sensor mount)

M3 Nuts:

4x (baseplate bowden hotend)

12x (baseplate bearings)

2x (baseplate belt holder

2x (bowden hotend mount)

1x (fan clamp

1x (fan duct)

2x (sensor mount) (+2x bl touch mount)

The x-carriage uses 2 LM8LUU bearings.

The distance between the linear rods is 45mm.

The distance between the extruder mount holes is 30mm for the ones in the center (through the belt-holder) and 23mm for the other holes (for bowden mount).

Note: I have adjusted this thing quite a lot since the first version.

I haven't tested the direct drive setup yet, but I'm pretty sure it won't work with the auto bed-leveling mounts. I will have to adjust it - but currently I only use the bowden setup, so I can not promise when I that will happen.

The bowden setup howerver works great.

Offsets for the BL-Touch:

Marlin 2:

NOZZLE_TO_PROBE_OFFSET { 37, 16, -2.50 }

Marlin 1:

X_PROBE_OFFSET_FROM_EXTRUDER 37

Y_PROBE_OFFSET_FROM_EXTRUDER 16

Z_PROBE_OFFSET_FROM_EXTRUDER -2.50

Note: you might need to adjust Z_PROBE_OFFSET_FROM_EXTRUDER depending on your sensor and hotend / nozzle.

Offsets for the LJ18A3-8-Z-BX:

Marlin 2:

NOZZLE_TO_PROBE_OFFSET { 37, 8, -0.7 }

Marlin 1:

X_PROBE_OFFSET_FROM_EXTRUDER 37

Y_PROBE_OFFSET_FROM_EXTRUDER 8

Z_PROBE_OFFSET_FROM_EXTRUDER -0.7

Note: you will need to adjust the Z_PROBE_OFFSET_FROM_EXTRUDER depending on how you mounted the sensor and your hotend / nozzle.

Big Update 2021-03-11

Added v2 for the bowden hotend mount.

Its a merged version of the hotend mount and the 40mm hotend fan duct (https://www.thingiverse.com/thing:3674791) which is easy to print and very stable compared to the fan duct clamped around the hotend. Furthermore, it supports the fan duct of the mk3 bear extruder which can be found here: https://github.com/gregsaun/bear_extruder_and_x_axis/blob/master/printed_parts/stl/common_to_all_versions/nozzle_fan_duct.stl

Another big improvement of this modification is that the cables for the hotend don't need to be bent anymore and can be routed straight to the back of the x-carriage.

Note: the clamping mechanism for the part cooling fan is not ideal yet.

I've just printed and assembled the first version and am printing with it right now.

Also just upgraded my second printer to this x-axis and added some pictures of assembly.

Update 2021-04-04

Added cable supports for vertical and horizontal cable alignment to the x-carriage. Also added pictures of both versions in my printers.

Update 2021-05-11

Had to reprint the LJ18A3-8-Z-BX mount and noticed that the hole was slightly too small, so I increased it a bit. Since my old mount bent due to the heat from the heated bed I now mounted it upside down. This way it is further away from the heated bed and should last longer.

Update 2021-07-31

Finally found a better solution for the part cooling fan and fan duct.

It uses a separate bracket attaching directly to the base-plate (v3_x_axis_part_cooling_fan_mount).

Its a lot stronger and more reliable than the clamp-solution - even though i never had problems with it.

Note: you need to either cut off the fan duct attachment from the old hotend-mount-cap or print the v3 (v3_x_axis_hotend_mount_cap_fan_mount.stl) to be able to use the new part cooling fan mount.

Update 2021-11-21

Added a kind of direct titan extruder mount, which allows changing from bowden to titan without touching the hotend itself. The direct extruder sits on top of the x-carriage and has a short bowden into the hotend.

It was designed for this titan extruder: https://www.thingiverse.com/thing:2570962

However, it should work for most other titan extruders as well, because the bowden allows for some deviation.

In order to not have to update your firmware when switching from bowden to direct extruder you might have to add an adapter to invert the extruder motor (at least i had to).

Furthermore, you have to add the steps/mm at the beginning of your gcode for the extruder you will be printing with (e.g. for the titan i use M92 E415, for the bowden BMG M92 E405).

With this setup its only a matter of a few minutes to switch from bowden to direct and vice versa.

I still need to work on the wiring, as its a bit of a mess at the moment ;-)

Update 2021-12-30

Finally had some time to improve the wiring.

I added a connector-mount for two 8-pin screw connectors on the back of the x-carriage.

Assembling the connectors is a bit tricky and requires soldering. However, the result is pretty nice as you can see in the pictures.

All cables for the fans, the thermistor and the z-probes run through those connectors now.

The x-endstop is now also attached to the x-carriage and uses the connectors.

The hotend heater cable is not routed through the connector, as I didn't have any pins left and I didn't want to route high current wires through the small connectors.

Same for the stepper cable in case you run the direct extruder.

I still need to upgrade my second printer which is currently running the direct extruder to make sure there are no issues with this setup.

Print Settings

Rafts:

No

Supports:

No

Resolution:

0.2

Infill:

30%

Category: 3D Printer Parts