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Direct drive Extruder Assembly

This page shows the different steps on assembling the Direct Drive  extruder

Direct Drive extruder Assembly


Needed parts

  • 1 Direct drive adaptor
  • 6 M3x8mm thermoplastic screws
  • 2 M3x20mm Thermoplastic screws
  • 1 M4x20mm screws

The starting point

Montage Direct Drive - point de départThis assembly is given for E3Dv6 or E3d Lite6 hot ends.

It may also be used for other types of hot ends

Your hot end bloc must already be assembled with the inductor probe on it.

It should already be installed on your X axis carriage in order to proceed the next steps.

The 30mm fan must be located on the right of the whole bloc with it’s original blue holder.

 

Direct Drive extruder Assembly

Direct Drive Adaptor

Direct Drive Adaptor

you will need this Direct Drive adaptor that allows to elevate the motor so that it’s free from any obstacle.

 

 

 

 

 

Installation de l'adaptateur Direct Driveplace the adaptor on top of the existing hot end holder.

 

 

 

 

 

 

 

 

Installation de l'adaptateur Direct Drive

Align the 4 holes with the one located on the hot end support.

 

 

 

 

 

Installation de l'adaptateur Direct DriveUse 4 M3x8mm Thermoplastic screws to hold both parts together

 

 

 

 

 

 

 

 


Direct drive Extruder Installation

Direct drive Extruder Installation

Place the extruder on top of it and align the 2 holes at the bottom with the one on the Direct Drive adaptor

It has 2 M3 holes that must align properly with the part below

 

 

 

 

 

 

 

 

 

Installation de l'extrudeur direct driveThe assembly should look like this

 

 

 

 

 

 

 

 

 

fixation de l'extrudeur direct drive

fixation de l’extrudeur direct drive

use 2 M3x20mm thermoplastic screws  and tighten both parts together

 

 

 

 

 

 

 

 

 

fixation de l'extrudeur direct drive

 

 

 

 

 

 

 

 

 

blower fan holder

blower fan holder

Use the blower fan holder that should look like the one on the picture.

It will allows to hold in place the blower fan that will cool down the freshly deposed melted plastic

 

 

 

 

 

 

 

 

blower fan installation

blower fan installation

you will nee  2 M3x8mm thermoplastic screws

The 2 fixation holes are located on the front of the hot end clamp.

 

 

 

 

 

 

 

installation du support de turbineDepending which heater block you are using you may adjust the height of the support so that the airflow is directed toward the nozzle tip.

 

 

 

 

 

 

installation du support de turbineOnce installed at the proper height you should get something similar.

 

 

 

 

 

 

 

 

 

installation du support de turbineThe blower fan is then inserted into the dedicated hole on the support. Make sure the blower fan intake is facing you.

 

 

 

 

 

 

 

blower fan fixation

blower fan fixation

Use 1 M4x20mm screw in order to hold the blower fan attached to it’s holder.

 

 

 

 

 

 

 

 

 


Direct Drive Extruder - final assembly

Direct Drive Extruder – final assembly

PDF 3D: Direct Drive extruder assembly

HotEnd Installation (AluHotEnd V7)

List of parts :

  • 1 assembled hot end (here AluHotEnd V7)
  • 1 inductor probe
  • 3 x M3x8 screws
  • 4 x M3x16 screws
  • 4 vis M3x20 screws
  • 1 x M4x20 screws
  • 1 Fan provided with the hot end(40 mm)
  • 1 couple of plastic parts to support the hot end
  • 1 blower fan
  • 1 blower fan support
  • 1 PTFE tube
  • (not providedi) screw driver

The bag provided should look like the one on the picture. It contains all the parts needed to achieve the assembly.

 

 

 

 


 

Once opened you should have the following parts

 

 

 

 

 


 

Take the hot end bloque assembled without the screws.

 

 

 

 

 


 

Open it.

You will have 3 separate parts:

  • 1 base support (here in the middle)
  • 1 inductive probe support (here on the left)
  • 1 wired hot end.

 

 


 

We are now going to prepare the base suppot to get it ready to be installed on the X axis carriage.

 

 

 

 


Take 2x M3x20 screws

 

 

 

 

 


 

Start to insert them inside the central holes.

Insert them untill they start to go out of the on the opposite side..

The assembly should look like the picture.

 


 

Behing it should look like this, with the screws at the border limit.

 

 

 

 


Now go on you X carriage.

The process is the same for both Scalar M and Scalar XL.

The hole colums allows you to adjust the height of the hot end later on if you need to.

But for now use the last to at the bottom of the carriage.

The pictures shows you which holes to take..

 

 

 


Place the base support in front of these holes.

Tighten the screws using very little strength so that you keep the whole assembly tight.

 

 

 


 

Now insert the hot end inside the dedicated groove as shown on the picture.

make sure that the wires are placed so that they go left.

 

 


 

Now take the inductor support.

Start to insert the 2 x M3x20 screws inside the dedicated holes. The picture tells you which one to use.

 

 

 


 

The screws should also slightly exit on the other side .

 

 

 

 

 


 

Place this support on top of the hot end and don’t touche the Screws yet!

Place the fan (here 40mm) on the right side of the assembly.

Use 4 M3x16mm screws and slightly screw them loose so that the fan keep it’s place.

 


The front view should look like this.

No screws are tighten yet.

The fan will hold properly the inductor holder.

If you tighten the inductor holder first, the fan hole might not be aligned anymore with it’s screws.

 


Once you have checked that all is aligned you can tighten the fan screws.

Note that the the screws of the inductor holder are yet not tighten.

 

 

 


 

Now you can finish to screw the inductor probe support.

The left screw should allow you to go a little bit further than the right one. It should make sure that the hot end is properly hold in place..

 

 


 

Now take the blower fan support as well as 2 M3x8mm screws (the shorter ones!)

This part allows to keep in place the blower fan in a vertical manner. It also guide the airflow toward the hotend’s nozzle tip.

 

 


 

Same here, start to insert the screws until they reach the other side of the plastic part.

The holes we are using here are the one at the 2nd row of holes starting from the bottom.

This design allows to adjust the height of the air flow based on the hot end you are using.

 

 

 

 

 

 

 


 

Here the screw driver shows you the holes to use to fix the blower fanholder.

They are the 2 holes located below the one used to secure the inductor support in place.

 

 

 

On this picture, the second hole to use.

 

 

 

 

 


 

Now place the blower fan holder so that the screws are aligned with their holes.

Here also make sure to go easy with the screws.

 

 

 


 

The side views of the assembly

 

 

 

 

 


 

The fan shroud should point to the nozzle tip.

 

 

 

 

 


Now take the blower fan

 

 

 

 

 


 

unroll the wires.

 

 

 

 

 


 

Place it on it’s support so that the fan output is placed toward the bottom.

At the top you will find 2 holes slightly shifted.

Place the fan so that the holding hole is aligned with 1 of the 2 holes on the support. Take the one you feel is best.

 


 

Use the last M4x20 screw (the bigger one) to keep the fan in place.

here we choose the top hole.

 

 

 


 

Once the blower fan in place, the setup should look like this picture.

 

 

 

 


 

The inductor probe comes last.

 

 

 

 

 

 


 

Remove the bottom nut and washer.

Take some time to place the remaining washer and nut slightly above the middle of the probe thread.

 

 

 


 

Insert the probe inside the last dedicated hole.

 

 

 

 

 


 

Try to place it so that the bottom blue end cap of it is slightly above the hot end tip. We will come back to it alter on when you will setup your electronics.

 

 

 


 

You can put back the washer and it’s nut to secure the probe in place.

 

 

 

 


Finish by placing the PTFE tube inside the pneumatic connector and you are done.

 

E3D V6 Full Metal hot end assembly

List of parts

  • 1 x heater blocks
  • 1 x heat break
  • 1 x nozzle
  • 1 x aluminum heat-sink
  • 1 x thermistor (100K Semitec 104GT2)
  • 1 x 12V 40W heat cartridge
  • 1 x 12V 30x30x10mm fan
  • 1 x high temperature glass fiber tube for thermistor
  • 2 x ferrules
  • 1 x M3x3mm screws
  • 1 x M3 washer
  • 1 x M3x10 screws
  • 1 x PTFE 80cm tube

Nozzle assembly:

  • Insert the nozzle inside the heater block. With the hex shaped head the closest possible of the heater block.
  • Tighten very slightly the nozzle against the heater block. Then un-screw it by 1/4 up to 1/2 of a turn.

 

 


  • Now screw the heat break in the same opposite hole as the nozzle.
    You must screw it until it’s deep inside.

 

 

 


  • Take 2 keys of the proper size and slightly tight them up.
    WARNING: Just tighten the whole thing very slightly, because the  aluminum thread inside the heater block is very fragile. You will need to tighten again anyway once the hot end is hot later on.

 

 

Thermistor assembly

  • Take the blue fiber glass tube.
  • Cut 2 parts of about 35mm long.
  • Insert the thermistor lead wires inside .
    Warning: The thermistor wires are extremely sensitive and fragile, so be very careful with them!

 

 

 


  • take the thermistor between your fingers and make a 90° angle on a 5mm length from the thermistor head.

 

 

 

 


  • Place the thermistor inside the small dedicated hole on the corner of the heater block near the nozzle.
  • Prepare the M3x4mmscrew and it’s washer, start to screw it inside the threaded hole next to the thermistor.
  • Make it so the thermistor wires are going on both sides of the screw as shown on the picture.
    Note: Check that the fiber glass insulator is still insulating the very end of the thermistor so that the legs of the thermistor have no contact between them.

Tighten the screw in order to clamp the fiber glass insulator and hold the thermistor in place.

 

 

 

 


Here is a view of the assembly once done.

  • Check that the blue insulator is still properly insulating the thermistor wires neat the thermistor head.
    If the wires are have contact on the heater block you will get some bad or wrong temperature readings leading to some failures later on.

 

 


 

Heater cartridge insertion :

  • Insert the heater cartridge so that the power cables are on the same side as the thermistor lead wires.
  • Center the heater cartridge on the heater block.

 

 

 


  • Insert a M3X10 screw inside the hole in order to clamp the heater cartridge inside the hater block.
  • Screw it until the heater block is slightly deformed in order to make sure the heater cartridge won’t get out of the heater block.

 

 

 


 

Thermistor wiring :

  • Strip the end of the black and red wires and insert 2 pieces of heat shrink tubing over them.

 

 

 


  • Place the Ferules on each thermistor blue insulator.
    If you place the larger part of the ferule  has shown on the picture it will help you for the next steps.
  • Inter-cross the lead wires of the thermistor with the one of the Red and black wires in order to make an electrical contact between them.

 

 


  • Now slide the ferule over the contact.

 

 

 

 


  • With a flat pliers, just smash the ferule in order to seal the contact between the 2 wires.
  • Do the same for the second thermistor wire.

 

 

 


  • Now bring the heat shrink tubing back over the smashed ferules.
  • You can use a lighter or a candler or a solder iron in order to shrink the tubing.
    This last step is to electrically insulate the ferule between them.

 

 


 

Heat sink assembly :

  • Take the heat-sink and screw it over the heat break with only 1 hand
    Tighten it only slightly with your hands, it’s enough.

 

 

 

 


 

Final step :

  • Take the PTFE tubing and slide it inside the heat sink hole as mush as possible.

 

 

 

 

 

Pictures under Creative Commons 3.0 licence

Source : http://wiki.e3d-online.com/wiki/E3D-v6_Assembly

Setup of the hot end auxiliary fan

List of parts :

  • 2 M3X25mm screws
  • 4 M3 washers
  • 2 M3 nuts
  • 1 blower fan
  • 1 GoPro fan support
  • 1 Fan shroud for blower fan

Take  1 screw,  1 nut and 2 washers as well as the GoPro fan support.

 

 

 

 

 


 

Now screw the GoPro Fan support on the blower fan, using the hole just next to the blower fan power wires .

Assemble it as follow: screw-washer –hole — washer – nut.

 

 

 


This photo shows the other side of the fan.

 

 

 

 

 

 


Place the whole assembly on the compatible support on the HotEnd block The photo shows you how to do it.

 

 

 


Secure it using the remaining fixation elements (M3x25mm screw, washer and nut).

You can place the screw head any way you want.

 

 

 


Now, tighten the whole thing enough so that the fan can be oriented but can stay in desired orientation.

 

 

 

 


Install the fan shroud as shown on the picture. This last part is to cool down  and harden the plastic just after it exists the hot end nozzle. You will need it when you will use PLA.

 

 

 


 

Rotate the fan block and adjust the orientation so that the blown air will cool down the bottom base of the nozzle.

Warning:  If the orientation is too much toward the hot end’s heater block, the fan will prevent the heater block from heating the plastic filament enough.

 

 


 

 

Hot End Installation (E3D V6)

This page is dedicated to the hot end Installation

Hot End Installation

Part list :

  • 1 x assembled hot end (here E3D V6)
  • 1 x inductance probe
  • 4 x plastic screws (provided with hot end)
  • 1 x fan provided with hot end
  • 4 x M3X20 screws thermoplastic
  • 3 x M3X8 screws thermoplastic
  • 1 couple of plastic parts to support the hot end (here with the marking E3DI andE3DII)
  • (not provided) 1 screws diver

Update:

Hot end E3D supportSince September of 2016 you should get this holder in the kit.

This holder is re-using the original E3D fan holder .

The assembly on the chassis is very similar to the following procedure, just consider inserting the Blue part on the hot end heat sink first.

Look closely to the red arrow and you will notice that the holder has to be installed so that the non flat side is set toward down.

The following picture should show you more details.

 

hot end suppot for E3Dv6

 

 

 

 

 

hot end suppot for E3Dv6

 

 

 

 

 

hot end suppot for E3Dv6

 

 

 

 

 

 


Installation of E3Dv6 hot end on the carriage

X Axis Carriage

X Axis carriage

The goal here is to screw the hot end support on the X axis carriage.

 

 

 

 

 

 

 

 


Take the screw diver and also the plastic part marked « E3DII« .(Note on the new plastic parts there is no marking because the side of the plastic part is used for the hot end fan.)

This part links the X axis carriage and the hot end .

It’s like a mould with an imprint for securing the hot end in place.

 


 

The X axis carriage also has several rows of 3mm holes.

Those holes allows to screw the previous part in place. Depending on the height of your heat bed and also of the one of your hot end nozzle you might want to use a different set of holes to increase or decrease the height of the hot end of a few millimetres.

In our current situation we are going to use the holes located on the outside of the part on the lowest row. The picture will confirm the holes to use.

 

 

Fixation du bloque de base du support de tête chauffanteOn the new version of the support no marking is visible

it should look like this one

 

 

 

 


 

The picture here shows the second hole to use to secure the hot end support .

 

 

 

 


Fixation du bloque de base du support de tête chauffante

Insert 2 M3X20 thermoplastic screws inside the holes on the side in order to keep the system attached

1 M3x8mm thermoplastic screw comes to strengthen the whole support

 

 

 

 

Fixation du bloque de base du support de tête chauffante

 

 

 

 

 

 


 

Now take the inductor support.

 

 

 

 

Note that on the new version of the plastic part, the inductive probe support has been removed and placed on the base holder instead.

 

 

Start to insert the 2 x M3x20 Thermoplastic screws inside the dedicated holes. The picture tells you which one to use.

Hot end clampHere is a picture showing the new compact plastic clamp

 

 

 

 

 

 

 

Assemblage du bloque de tête chauffante

Assemblage du bloque de tête chauffante

This new plastic part is clamping the hot end inside it’s groove.

 

 

 

 

 

 

 

Hot End InstallationOnce finalized the assembly should look like this

 

 

 

 

 

 

 

PDF 3D:Final assembly of the hot end support for E3D6

 

Update:

Skip this part if you have the new Holder system

 

 

 


Place this support on top of the hot end and don’t touch the Screws yet!

Place the 30mm fan (here on the picture  40mm) on the right side of the assembly.

Use 4 wood screws and slightly screw them loose so that the fan keep it’s place.

 

 


The front view should look like this.

No screws are tighten yet.

The fan will hold properly the inductor holder.

If you tighten the inductor holder first, the fan hole might not be aligned any more with it’s screws.

 


 

Once you have checked that all is aligned you can tighten the fan screws.

Note that the the screws of the inductor holder are yet not tighten.

 

 

 


 

Now you can finish to screw the inductor probe support.

The left screw should allow you to go a little bit further than the right one. It should make sure that the hot end is properly hold in place.

 

 


 

Now take the blower fan support as well as 2x M3x8mm screws (the shorter ones!)

This part allows to keep in place the blower fan in a vertical manner. It also guide the airflow toward the hot-end’s nozzle tip.

 

 


 

Same here, start to insert the screws until they reach the other side of the plastic part.

The holes we are using here are the one at the 2nd row of holes starting from the bottom.

Note that this part was made for AluHotEnd  and mostly applies to E3D hot end.

As E3D hot end size is different from AluHotEnd you may need to use another set of holes. If you are not sure read the following steps below before doing anything.

This design allows to adjust the height of the air flow based on the hot end you are using.

 

 

 

 

 

 

 


 

Here the screw driver shows you the holes to use to fix the blower fan holder.

They are the 2 holes located below the one used to secure the inductor support in place.

 

 

On this picture, the second hole to use.

 

 

 

 

 


 

Now place the blower fan holder so that the screws are aligned with their holes.

Here also make sure to go easy with the screws.

 

 

 


The side views of the assembly

 

 

 

 

 

 


 

The fan shroud should point to the nozzle tip.

 

 

 

 

 


Now take the blower fan

 

 

 

 

 


Unroll the wires.

 

 

 

 

 


 

Place it on it’s support so that the fan output is placed toward the bottom.

At the top you will find 2 holes slightly shifted.

Place the fan so that the holding hole is aligned with 1 of the 2 holes on the support. Take the one you feel is best.

 

 


Use the last M4x20 screw (the bigger one) to keep the fan in place.

here we choose the top hole.

 

 

 


Once the blower fan in place, the setup should look like this picture.

 

 

 

 


 

The inductor probe comes last.

 

 

 

 

 


Remove the bottom nut and washer.

Take some time to place the remaining washer and nut slightly above the middle of the probe thread.

 

 

 


Insert the probe inside the last dedicated hole.

 

 

 

 

 


Try to place it so that the bottom blue end cap of it is slightly above the hot end tip. We will come back to it alter on when you will setup your electronics.

 

 

 

 


You can put back the washer and it’s nut to secure the probe in place.

 

 

 

 

 


Finish by placing the PTFE tube inside the pneumatic connector and you are done.