the bondtech extruder for 1.75 & 3.0 mm filament for … extruder assembly...assembly manual...

Assembly manual V2.3 2015-05-16

1

The Bondtech Extruder for 1.75 & 3.0 mm filament for use as a Bowden or a direct Extruder.

The extruder uses high-quality industrial pneumatic push-fit fittings for attaching the bowden

tube. It has also thread inserts to have a strong connection of the fasteners. The mount for

the hotend is a standard “Groovemount” that makes it possible to use the E3D hotends

aswell as others following this standard.

This new revolution in design utilizes the Bondtech Dual Drive Technology with precision

CNC-manufactured parts which gives the markets best performance and reliability.

Thanks for your support making this project a reality!

This work is licensed under a Creative Commons Attribution 4.0 International License.

http://creativecommons.org/licenses/by/4.0/


2


3

Contents BOM (Bill Of Material) ............................................................................................................ 4

Assembly ............................................................................................................................... 5

Step 1, Primary drive wheel ............................................................................................... 5

Step 2, Holder .................................................................................................................... 5

Step3, Extruder housing back ............................................................................................ 6

Step 4. Secondary drive wheel .......................................................................................... 6

Step 5. Bowden adapter .................................................................................................... 7

Step 6. Front housing ......................................................................................................... 7

Step 7. Set-screws ............................................................................................................. 8

Step 8. Electrical connector ............................................................................................... 8

Maintanance ...................................................................................................................... 9

Groovemount ..................................................................................................................... 9

Geared stepper motor type 1 ................................................................................................10

Geared stepper motor type 2 ................................................................................................11

Steps / millimeter ..................................................................................................................11

FDM-printed components, thread bushing ............................................................................12

Direct mount of Hotend .........................................................................................................14

STL files ...............................................................................................................................15


4

BOM (Bill Of Material) Description Qty Image

Geared Nema17 stepper, two types used, with integrated cable or not.

1

Primary drive wheel 1

Secondary drive wheel 1

Extruder housing front 1

Extruder housing back 1

Holder 1

Screw M3x10 2

Screw M3x30 2

Setscrew M3x10 2 Setscrew M4x3 1

Bowden adapter (optional) 1

Screw M5x10 1

Nut M5 1

Axle 4x25 1

Washer 4.3x9x0.5 1


5

Assembly

Step 1, Primary drive wheel

1. Insert the setscrew M4x3 into the threaded M4 hole with a 2 mm allen key in the

primary drive wheel.

2. Align the Primary drive wheel with the flat part of the output shaft of the gearbox.

3. Measure ca 1.5 mm between the top of the drive gear and the top of the gearbox

shaft. Put on the rear and front extruder housing on temporarily and verify that the

center of the drive gear aligns with the small arrow in the housing, if not adjust the

position of the drive gear.

(Depending of your print this could vary slightly and needs to be adjusted)

4. Tighten setscrew firmly,! Do not over tighten!

Step 2, Holder

1. Place the holder onto the gearbox, insert M5x10 screw into the two holes and tighten

lightly with a 4 mm allen key. Orient is as you like to fit your printer with respect to the

electrical connection.

Align


6

Step3, Extruder housing back

1. Place the extruder housing back onto the 22 mm cylindrical section of the gearbox.

2. Align screw holes of the extruder housing back with the M3 holes in the gearbox and

the aligning feature with the holder.

3. Insert M3x10 screws in recesses of the extruder housing back.

4. Tighten the M3x10 screws with 2.5mm allen key

Step 4. Secondary drive wheel

1. Insert shaft 4x25 into the recess on the back extruder housing

2. Place 1 washer onto the shaft. Add a small amount of lubrication (grease/oil) to the

shaft and on the gear section of the drive wheel.

3. Place the secondary drive wheel on the shaft with the gear side towards the motor.

4. Place the second washer on the drive shaft on top of the drive gear.


7

Step 5. Bowden adapter

If you are going to use a bowden adapter (from Bondtech or self-printed) place the adapter in

the groove with the push-fit connector facing out from the extruder.

Step 6. Front housing

1. Insert the M3x30 crews and thighten with a 2.5mm allen key


8

Step 7. Set-screws

1. Insert the two M3x10 set screw on the right side of the extruder, take care that it

starts the thread straight and screw them in to about 1 mm above the surface of the

extruder housing.

2. Optimum position of the set screw is when the top of the set-screw is 0.5 mm over the

housing surface.

Step 8. Electrical connector

1. Insert the supplied cable into the motor, take care of the orientation feature.

Depending of the type of motor supplied it could be with a fixed cable or a removable

as on the image below.


9

Maintanance

Disassemble the extruder when you see debris on the drive wheels and clean the drive

wheels from plastic debris and make sure the gear tooth are clean. After cleaning apply

some grease inside the needle bearing of the secondary drive wheel and also on the gear

teeth’s.

Groovemount

The extruder uses a fixing system for the hotend known as the Groovemount. Hotends that

follows this standard are possible to use. Example E3D V5 and V6 hotends.

Image from E3D:s website http://wiki.e3d-online.com/wiki/File:DRAWING-V6-175-SINK.png

The ownership of this image is E3D Ltd.

http://wiki.e3d-online.com/wiki/File:DRAWING-V6-175-SINK.png


10

Geared stepper motor type 1 The supplied motor is a two-phase Nema17 stepper motor with an integrated planetary

gearbox with 5.18:1 ratio. This motor has an integrated cable without connectors.

Electrical connection Dimensions

Specifications:

Gearbox:


11

Geared stepper motor type 2 The supplied motor is a two-phase Nema17 stepper motor with an integrated planetary

gearbox with 5.18:1 ratio with a connector placed onto the motor. The supplied cable has a

connector on each end.

Steps / millimeter Use 491 steps / millimeter (1.75mm) and 510 steps/mm (3.0mm) as a start point when using

16 bit micro stepping, fine tune the steps by cutting off the filament flush with the extruder,

then extrude 100 mm and measure the extruded length. Example: If you measure 97 mm

then change the steps/mm setting in your firmware to 491 * (100/97) = 506 steps/mm.


12

FDM-printed components, thread bushing The new design features thread inserts in order to create a strong thread for the set-screws

and also for the mount. Use the following method to assemble the thread bushings that were

with your kit.

1. In order to properly mount the thread bushings you will need a soldering iron,

normally 30W is sufficient but 100W will make it quicker. You will need to make two

custom tips for your soldering iron according to below illustration, if you have the

possibility to use copper it works best but steel or brass and also aluminum should be

ok. The big tip below is for my 100W soldering iron and the small is for my 30W iron.

Check your soldering irons required diameter for the tip and adjust it accordingly

2. Place the M3 insert in the side of the extruder housing, you might need to adjust the

diameter with a drill depending of you printers calibration. Recommended diameter is

3.8-4.0 mm, ! Do not drill too deep since you will damage the housing!

D L D2*

M3 Ø2.4 4.5 Ø 3.9

M5 Ø 4.1 5.7 Ø 8.0 Custom tip for M5 insert

Custom tip for M3 insert

D

D

L

L

D2

D2


13

3. Keep the soldering iron vertical at 90 degrees to ensure that the thread bushing goes

in straight like below. Let the heat go into the bushing before applying pressure, press

down gently until the top of the insert is flush with the housing.

4. Use the same procedure for the other bushings


14

Direct mount of Hotend The extruder have the possibility to mount a Hotend directly into the housing bottom part.

The mount is equipped with a protrusion that grips the Groove Mount of the hot end.

Since there is a PTFE tube going into the heatsink there is tricky to assemble it. You will

need to cut a small piece of the PTFE-liner and insert into the recess of the housing before

you place the hotend into the housing like below.

The new version is without the central protrusion of the front housing part that will allow you

to have one ptfe piece instead of two. The protrusion is still in the back housing part that will

hold the hotend secure in place. STL files are available on www.bondtech.se/stl


15

STL files The latest stl-files for printing your housing part you will find under www.bondtech.se

Good luck with your Bondtech Extruder!

If you have any questions please contact me by mail or telephone.

Lummervägen 5

33155 Värnamo

Sweden

e-mail: [email protected]

phone: +46702220193

paypal: [email protected]

web: www.bondtech.se

VAT-registration number: SE556995564301

mailto:[email protected]

http://www.bondtech.se/

the bondtech extruder for 1.75 & 3.0 mm filament for … extruder assembly...assembly manual...

Documents