Ender 3 Speed Upgrade

WIP - TBA (as of 10/10/2023):

• Full specs (will be updated once I am done testing everything out)
• Y-axis upgades
• Z-axis upgrades

Outline

A series of upgrades for an Ender 3 that aim to transform a stock printer into a fast and reliable machine, able to produce excellent quality 3D prints.

This whole series of upgrades obviously might not make sense for everyone, considering that you can get a e.g. a Voron 0.x kit or an A-1 for a similar amount of money.

Most of the parts listed in their respective categories can be had from Aliexpress. Waiting for sales or "spend and save" promotions will save you a good chunk of money.

Specs:

• Build Size: 210 x 210 x 210 mm (=210 mm^3)
• Max. Motion System Speed (stock motors, aluminum bed carriage): ~250 mm/s (limited by the stock Y-axis motor)
• Max Printing Speed: TBA mm/s
• Max. Printing Speed (Quality): TBA mm/s (estimated at least 300 mm/s)
• Acceleration (as set in printer.cfg file): 8000 mm/s^2
• Input Shaper Settings (tested many times over multiple different probe points):
  • X-Axis: ZV w/ ~20k mm/s^2 Acceleration, ~0.03 Dampening Ratio 
  • Y-Axis: TBA
• Max. Volumetric Flow Rate (OrcaSlicer max flowrate test): ~50 mm^3/s (PLA @ 260 °C, 0.6 mm CHT Clone Nozzle)*

* this is the result from an initial max flow rate test I just did, as I thought the limit of the extrusion system would be sitting someplace around the 50 mm^3/s mark, but I am not sure if I have hit its limit yet… there are hints of die swell on two out of the 3 bends in the test print, but I'd say it's not conclusive. Maybe there's a handful of mm^3/s to be squeezed out of it yet, will test further and update you when I do.

Visit the links below for a detailed breakdown of each upgrade:

X-Axis Upgrades (+ Toolhead)

Y-Axis Upgrades

Coming Soon :)

Z-Axis Upgrades

Coming Soon :)

Electronics (Total Cost: incl. mainboard: ~110€ - w/o mainboard: ~80€):

• SKR MINI E3 V3.0
• MKS Pi + eMMC Memory Module + USB WiFi Dongle: https://www.aliexpress.com/item/1005004417871231.html (obviously, any Pi or Pi alternative will  work).
• BTT U2C v2.1: https://www.aliexpress.com/item/1005004243206192.html
• 0.5 m Type A to Type C USB Cable (angled): https://www.aliexpress.com/item/1005001626467639.html

Maybe it'd be cheaper if one would use the BTT Manta E3EZ V1.0 + a CM + a CAN hat instead of all that, but since I already had the mainboard in place along with the Pi when that released, it wouldn't make sense for me to shell out the extra cash for the board - however, someone attempting this build that hasn't already invested in a motherboard upgrade should probably consider this.

Various QoL Upgrades (optional):

• X/Y Axis Belt Tensioners: https://www.aliexpress.com/item/1005004392680334.html
• Angle Brackets (to stiffen the printer's frame): https://www.aliexpress.com/item/32870543302.html
• SKR MINI E3 V2.0/V3.0 DCDC5V V1.0 Power Module (for powering your Neopixel strip through the mainboard header): https://www.aliexpress.com/item/4000474224890.html
• Neopixel LED Strip: https://www.aliexpress.com/item/1005004289391906.html