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View Full Version : Introducing... The Toranado Precision Geared 1.75mm Extruder



bolsoncerrado
02-23-2016, 10:09 AM
The Toranado Precision Geared 1.75mm Extruder

by wesleyweber (http://www.thingiverse.com/wesleyweber), published Jan 5, 2016






http://thingiverse-production-new.s3.amazonaws.com/renders/ec/32/84/0a/bb/2eda44c8c5ab8077a3d29d783c6e14c5_preview_featured. jpg


http://img.youtube.com/vi/nE5W35HkDh8/0.jpg








Summary

UPDATE 2-22-2016 - A couple of Makers have agree to test bed-leveling on the Toranado, so I just uploaded two .STL files for compatibility with the BL Touch Auto Bed Leveling Sensor (http://www.ebay.com/itm/201523795715?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT). You will need to print the following two files:



tpge-40mmfanduct-bltouch.stl: alternate 40mm fan duct with BL Touch mount
tpge-bltouch-cover.stl - a cover to hide the BL Touch wiring

I have posted an image (http://thingiverse-production-new.s3.amazonaws.com/renders/83/62/c7/0a/20/3ab7f0cf029422213c61627511865330_preview_featured. jpg) of the Toranando using the sensor and additional information on this sensor can be found Here (https://www.indiegogo.com/projects/bltouch-auto-leveling-sensor-for-3d-printers#/story).

This sensor looks promising, as it is smaller and lighter than inductive sensors, and works on any surface.

UPDATE 2-22-2016 - I have uploaded tpge-shaftcollar.stl to the list of .STL files. If you can find a local supplier for a 3mm Set Screw (http://www.mcmaster.com/#92029a100/=118mqpu) this will eliminate the need for the Shaft Collar in the BOM.

Hardware Kits NOW AVAILABLE
Precision Gear and Shaft Kit - Sold Out
Fastener Kit - Sold Out
Both Toranado Kits - Sold Out

The Toranado Precision Geared 1.75mm Extruder
Intro (https://www.youtube.com/watch?v=nE5W35HkDh8&feature=youtu.be)
Build Instructions (https://thingiverse-production-new.s3.amazonaws.com/assets/0f/2c/fc/85/80/tpge-buildinstructions.pdf)
e_steps_per_mm Gear Calculation (http://thingiverse-production-new.s3.amazonaws.com/renders/8d/1c/56/bc/cb/95614b24236483ba7efa4f8bc28e9ea2_preview_featured. jpg)


Significantly lighter than NEMA-17 geared Extruders
All-in-one
Precision Geared
Uses Ultibot's High Performance MK7 Drive Gear
Modular Design - All parts are easily printable without structure and in your material of choice (PLA/ABS/PETG).
Designed for use with E3Dv6 1.75mm Universal
Attractive (like the one who designed it*).

*Note: There is still some minor discussion as to the validity of the designer being attractive.

AVAILABLE TORANADO X-CARRIAGE MOUNTS
i3 8mm X-Carriage Mount (http://www.thingiverse.com/thing:1302584)
i3 10mm X-Carriage Mount (http://www.thingiverse.com/thing:1297618)
*Also compatible with i3 Rework (http://www.thingiverse.com/thing:119616) and typical 23x23mm x-carriage hole patterns.

Why the Toranado?
We have discussed in our video a few reasons why we developed the Toranado Precision-Geared Extruder. Here is some essential background info:
Starting Out with Your Typical Pack-in Kit
Like most hobbyists who choose to build a DIY 3D-printer, the process begins with ordering a frame and kit with the essential 3D-printed components. For popular printers based on the Prusa i3, these kits usually include a "Wade"-style NEMA-17 extruder with 3D-printed gears and a hobbed M8 bolt for driving the filament. This is where we started too!
Identifying the Problems
As we began using our "Wade" extruder, it wasn't too long before we noticed issues with our setup:


We noticed that filament would sometimes slip or strip on the hobbed bolts from our pack-in kits.
The options for integrating a 30mm heatsink fan with a 40mm bed cooling fan were limited and clunky - our setups ended up looking silly with large fan ducts hanging off to the side.
We also had problems with the gear setup. Getting the 3D-printed gear concentric and true to the hobbed-bolt was problematic. And because 3D-printed gears typically have a large pitch between gear teeth, it was difficult to get an adequate gear differential to generate driving torque. To solve this, higher-torque NEMA-17s are typically used - but these motors are heavy (most NEMA-17s weighing in at over 300 grams). In the end, regardless of what we tried, our all-in-one solutions were heavy, bulky, and quite simply - ugly.

All-in-One or Bowden?
One solution was to remove the mass from the print head by pulling the motor and drive gear off to the side (a "Bowden" setup). This, however, introduced another problem we had to deal with - retraction accuracy and ooze from the nozzle. In the end, we were unable to get around this - this problem seems as inherent to the Bowden setup as weight is to and all-in-one. We decided to improve the all-in-one.
The Solution - An "All-in-one" with Balance and Appeal


First, we decided to strike that perfect balance by using precision gears with a higher gear differential, coupled with a lightweight NEMA-14 motor. The results have been wonderful. We have both adequate torque to drive the 1.75mm filament and much less mass on the print head (some NEMA-17 motors weigh as much as our entire extruder!). The retraction accuracy with the precision gears has also been spot on.
Since our precision gears also mount on a 5mm shaft, we have the added benefit of eliminating the hobbed bolt and replacing it with a precision drive gear. The MK7 drive gear for 1.75mm filament has been perfect, eliminating the issues with filament slipping or stripping.
And since we integrated both the heatsink and bed cooling into the extruder assembly itself, we have a small and compact precision extruder with aesthetic appeal.

We feel that the Toranado Precision Geared Extruder strikes the perfect balance between weight and precision, making it a wise choice for hobbyists looking to improve their overall print quality and accuracy - and it is nice to look at too!
How I Designed This

What I did was start designing an extruder, and at each stage I asked myself the question, "Would an idiot do this?" If they would, I did not do that thing.
Bill of Material

Fasteners, Washers, Nuts, Springs and PTFE Tubing
NOTE: All of these items are included in the Toranado Precision Geared Extruder Fastener Kit
(3x) M3x14 Button-Head Machine Screw (http://www.mcmaster.com/#92095a168/=115fqga)
(1x) M3x22 Button-Head Machine Screw (http://www.mcmaster.com/#92095a473/=115fr0s)
(4x) M3x30 Button-Head Machine Screw (http://www.mcmaster.com/#92095a187/=115frcm)
(2x) M3x5 Self-Tapping Screw (http://www.ebay.com/itm/M3-x-5mm-Phillips-Cross-Pan-Head-Self-Tapping-Screws-Black-Oxide-50-pcs-/262260101364?hash=item3d0feb90f4:g:WgsAAOSwv-NWVmhO)
(3x) M3x14 Self-Tapping Screw (http://www.ebay.com/itm/M3-x-14mm-Phillips-Cross-Pan-Head-Self-Tapping-Screws-Black-Oxide-50-pcs-/252267165751?hash=item3abc4b7837:g:WgsAAOSwv-NWVmhO)
(12x) M3x18 Self-Tapping Screw (http://www.ebay.com/itm/M3-x-18mm-Phillips-Cross-Pan-Head-Self-Tapping-Screws-Black-Oxide-50-pcs-/252267165920?hash=item3abc4b78e0:g:WgsAAOSwv-NWVmhO)
(6x) M3 Stainless Steel Washer (http://www.mcmaster.com/#93475a210/=115g17v)
(9x) M3 PTFE Heat- Isolation Washer (http://www.mcmaster.com/#95630a620/=115g1xk)
(5x) M3x4mm Brass Knurl Nuts (http://www.ebay.com/itm/100pcs-M3-4mm-H62-Brass-Knurl-Nuts-DIY-Accessories-/161973195326?hash=item25b65ad23e:g:nxYAAOSwx-9WubBu)
(2x) M3 Nyloc Nut (http://www.mcmaster.com/#90576a102/=115g3lt)
(1x) PTFE Tubing 4mmOD 1.8mmID - 64mm length (http://www.amazon.com/Teflon-Filament-RepRap-DIY-Printer-Parts/dp/B00FGI6I84/ref=sr_1_1?s=industrial&ie=UTF8&qid=1439995886&sr=1-1&keywords=B00FGI6I84)
(3x) PTFE Tubing 5mmOD 3mmID - 8.25mm length (http://www.mcmaster.com/#52335k53/=115g61j)
(2x) Compression Springs
(http://www.homedepot.com/p/Everbilt-Spring-Assortment-Kit-84-Pack-15642/202045461)
Precision Gearing and Shafting
NOTE: All of these items are included in the Toranado Precision Geared Extruder Gear and Shaft Kit
(1x) 94T 48P Acetal Main Gear (https://servocity.com/html/48_pitch_acetal_hub_gears__1_8.html#.VsNPrflVhBc)
(1x) 19T 48P Hardened Steel Motor Pinion Gear (http://www.amazon.com/Robinson-Racing-Pitch-Machined-Pinion/dp/B00681QH7A/ref=sr_1_fkmr1_1?ie=UTF8&qid=1455640599&sr=8-1-fkmr1&keywords=Robinson+Racing+2019+Motor+Pinion)
(1x) Aluminum Gear Hub w/ 5mm bore and set screw (https://servocity.com/html/0_770__set_screw_hubs.html#.VsNQfPlVhBc)
(1x) 5mm Stainless Steel Precision Shaft - 50mm Length (https://servocity.com/html/5mm_precision_shafting.html#.VsNQx_lVhBc)
(1x) 5mm Stainless Steel Precision Shaft - 25mm Length (https://servocity.com/html/5mm_precision_shafting.html#.VsNQx_lVhBc)
(4x) 6/32 3/8" Length Truss-Head Machine Screws
(https://servocity.com/html/6-32_truss_head_phillip_machin.html)
Hardware
(1x) e3dv6 1.75mm Universal Hot End - Full Kit (http://e3d-online.com/E3D-v6/Full-Kit/v6-1.75mm-Universal)
(1x) NEMA-14 Stepper Motor - 28mm length (https://www.pololu.com/product/1208)
(1x) 40x40x10mm 12vdc Bed-Cooling Fan (http://www.amazon.com/Case-40x40x10mm-Ball-Bearing-3-pin/dp/B002OFL1J8/ref=sr_1_2?ie=UTF8&qid=1455641376&sr=8-2&keywords=40x40x10+fan)
(3x) 5x16x5 625zz Radial Bearings (http://www.vxb.com/625ZZ-Bearing-5x16x5-Shielded-Miniature-p/625zz20-1.htm)
(1x) Ultibot MK7 1.75mm Drive Gear (http://www.ultibots.com/drive-gear-1-75mm-filament/)
(1x) 5mm Shaft Collar w/ Set Screw (http://www.mcmaster.com/#57485k65/=115gjgs)
Print Settings

.STL files and recommended print settings (with a 0.4mm nozzle)


tpge-extruderbase.stl: 4 Perimeters, 0.2mm layers, 25% infill
tpge-gearprotector.stl: 2 Perimeters, 0.2mm layers, 21% infill
tpge-40mmfanduct-wprintpad.stl: 2 Perimeters, 0.2mm layers, 21% infill
tpge-clamp-hotend.stl: 2 Perimeters, 0.2mm layers, 21% infill
tpge-idler-wprintpad.stl: 2 Perimeters, 0.2mm layers, 25% infill
tpge-decorationcover.stl: 2 Perimeters, 0.15mm layers, 21% infill
tpge-smallgearcover.stl: 2 Perimeters, 0.2mm layers, 21% infill
tpge-spacer-wprintpad.stl: 2 Perimeters, 0.2mm layers, 21% infill
tpge-bearingcover.stl: 2 Perimeters, 0.2mm layers, 21% infill
tpge-idler-tensioner.stl: 2 Perimeters, 0.15mm layers, 21% infill
tpge-fancover-40mm.stl: 2 Perimeters, 0.15mm layers, 21% infill
tpge-fancover-30mm.stl: 2 Perimeters, 0.15mm layers, 21% infill
tpge-gearcover-94t.stl: 2 Perimeters, 0.15mm layers, 21% infill
tpge-hubcover-wscrews.stl: 2 Perimeters, 0.15mm layers, 21% infill