Revo Connect Redux

Introduction

I really like the modular design of Revo Connect, especially since I keep getting more nozzles (cough✨ObXidian✨cough). However, the original design does have some minor annoyances (very loose fit, text doesn't always print well). I've seen remixes that try to fix these issues, but they tended to be too tight, and most of them change the label font. So, what started out as a quick STEP file modification turned into a multi-day project where I fully recreated the design in FreeCad. I've made a number of improvements:

• Debossed and beveled text has no overhangs, and prints beautifully
• Tightened the dovetail tolerance so that there is no more wobble and sections don't fall apart if you pick them up in the wrong place without making the connection so tight that it becomes difficult to add and remove sections
• Reworked the curved section on top to make it print more cleanly (no more large visible steps)
• Backwards-compatible with E3D's design, allowing you to mix-and-match as long as you don't have OCD :p
• Fully parametric (see below)

Printing

I recommend using PETG with a 0.15mm layer height. 0.2mm should also work, but the top will likely have more visible steps. A few other notes:

• Printing 4 at once gives each layer more time to cool and improves surface finish.
• Use 15 or 20% gyroid infill. I initially tried to use grid, but had issues with parts detaching from the bed.

Modifying

Note: if you want to modify the FreeCad file, you will need to download the Kanit fonts (this is what E3D uses on their website) and extract Kanit-Bold.ttf to the same directory as revo-connect.FCStd.

The FreeCad file is organized into multiple bodies, and all labeled versions clone the base redux body. This means that any modifications made to redux will carry over into all of the labeled versions. Depending on what you change, modifying the base model may break the others. Basic edits such as adjusting the dovetail size work correctly.

Most of the text configuration is parameterized off of the 0.4mm variant, so changing properties such as text position/depth or the bevel angle will propagate to all of the other models as well. Note that changing the font will almost certainly break several variants, as I needed to manually add fillets in places to get the chamfer tool to work properly.

Following is a list of parametric features that apply across multiple sizes: