Ender Cross Support Feet (Alpha) - Ender 3 V2, Neo

Ender Cross Support Feet

Re-thinking the Ender feet support configuration by taking into account the frame design, moving masses, and dampening for high speed printing.

Designed and tuned with ADXL resonance testing (over 300 tests on the stock Ender motion system), and focused on strengthening the Y axis to achieve high print accelerations using Klipper and input shaping. 

Access to the front tool box is obstructed. Stuff it with foam to dampen the vibration noises :)

Features:

- Capable of reaching ZV - 10000mm/s/s accel on the Y axis
- Supports 42-40 stepper motor on the Y axis
- Supports 9mm belts (need a different front Y tensioner)
- 60mm height clearance for custom cases or fans

Requires:

- Stepper with a D shaft and adjustable pulley

- Longer Y Belt

- Y Limit Switch Mount

Print

4 Perimeters
5 top/bottom layers
40% Cubic Infill  
Supports only for the A/B stepper mounts on the outer/bottom joining extrusions.

Print the test model to check the V slot fit for the front foot.

 

Hardware

-M3 40mm x4
-M5 30mm x2
-M5 16 x4
-M6 16 x4

-M5 Hex Nuts x4
-M5 T Nuts, or M5 Hex Nuts (that fit into the V slot) x4

-Feet Pads

Setup

The feet will be unbalanced by design. You have to use spacers to balance the printer depending on your felt setup.

Y belt tuned at 115hz over 245mm
X belt tuned at 100hz over 283mm
 

Assembly:

The rear foot's hex nuts are inserted though the middle V then pushed sideways. It looks challenging, but I managed to fit them faster than I though I would. 

Tuning Tips:

-Most of the weight should rest on the Front and Back feet.
-The Middle Left foot should take most of the side load due to the heavy left center of mass.
-The Middle Right foot should almost be in the air, freestanding. 
-The highest performance on the Y axis is ideally achieved by using only the front and rear supports. The side supports induce extra resonances, but are needed for lateral support, so a compromise has to be achieved.

Setup:
-Double stack the felt on the Front and Back feet.
-Place thin felt pads on the outer edge of the Middle Side feet.
-Use the printed spacers to level your printer against the floor. 
-Start by leveling the feet in the Y direction by placing a measuring level tool directly on one of the side extrusions. Insert Spacers between the floor and the pad.
-Level the X direction starting with the Middle Left foot. Place a measuring level tool at the very top of the cross extrusion that hold the two Z extrusions. Insert Spacers. (It is better if it leans a tiny bit on the left)
-Move to the Middle Right foot and make sure that it doesn't hold any weight and it almost floats in the air. Insert spacers if needed, but not so it puts any pressure on the foot. Your Resonance testing result will depend the most on this side. The more it is supported, the worse the Y result is. The more it floats, the better, but it will affect the X wobble.
-If the resonance tests are not satisfactory on Y, try raising the Front foot.

Credits: 
Y motor mount based on DaRk_dOg's Ender Switchwire conversion.

Enjoy!