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Anycubic i3 Mega X-Carriage

MK4 - e3d v5 & v6 Version + Marlin 2.0 Firmware

This is the new generation (MK4) of the previous MK3 design of my famous free-to-use X-Carriage for the Anycubic I3 Mega (S)

The MK4-Design was completely re-designed from scratch for most parts to gain more flexibility and a better user experience.
Thanks to all supporters of this project & their suggestions/ideas for new stuff which I took for improvements of this new generation of the Carriage!

Check out the (free to use) Direct Drive Upgrade

The whole MK3 project is included in the MK4 project folder which can be downloaded here.

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The main design features:

• e3d v5 (stock), e3d v6 & e3d v6 volcano hotends are supported
• Fully new X-Carriage with better & more flexible bearing holding system
• Faster Hotend change due to improved Carriage system
• Less weight compared to MK2 & MK3
  (mainly due to weight reduction of the mandatory fasteners)
• Increased build volume in z direction (205-210mm)
• Extremely effective belt tensioners included in the Carriage
• PCB on the backside of the carriage
• New fanduct design which combines the powerful cooling from the MK3 with an easier assembling process and a more effective blower position & inflow
• BLTouch usage possible (probe offset: X=+29, Y=-15)
• Usage of Linear Ball Bearings (LM8LUU) or slide bearings (IGUS) in the same Carriage
• Either hex nuts or threaded brass inserts can be used
• Cable Harness guiding with spiral tube or drag chain (10x20) possible

Instructions on the stl-files, print settings & assembling process can be found in the project folders as a pdf file which is name '00_Instructions(...).pdf'. The assembly instructions are summarized in an instructional video which can be found here:
https://www.youtube.com/watch?v=LadxXGYkU20

The project also contains the newest Marlin 2.0.6 Firmware on the one hand for manual mesh bed leveling (MBL) and on the other for automatic bed leveling (ABL) with BLTouch. Special Thanks go to Christian H. for adapting and managing the Firmware part for the MK4 project. https://www.thingiverse.com/thing:4358979/
You DO NOT have to change the firmware if you do not want to, its optional.

Print/Slicing settings are given in the PDF-instruction files!

The project folder "MK4_Project_Repo.zip" contains the following sub-folders for the project organization:

• 01_MK4_Hex_Nuts.zip
  (In this variant all bolts are fixed with hex nuts)
  • 01_Standard
  • 02_BLTouch
• 02_MK4_Threaded_Brass_Inserts.zip
  (In this variant most bolts are fixed with brass inserts)
  • 01_Standard
  • 02_BLTouch
• 03_Various_Parts.zip
• xx_MK3_Carriage_repository.zip

Note:
03_Various_Parts.zip contains additional parts which are optional to be used for example a dragchain rear bracket for using a 10x20 drag chain, an axialfan adapter for using axialfan as partcooling, a second alternative fanduct (B) which has a different mounting position of the fan in case of unwanted vibrations with fanduct (A) & a carrier plate for the e3d v6 volcano hotend.

If you want to use a drag chain (10x2) you just must print the ´vp02_Dragchain_Rear_Bracket.stl´ instead of the regular rear bracket, additionally you have to print ´vp03_Dragchain_Extruder_Mount.stl´ which is mounted at the extruder. To mount the drag chain you will need 4x M3x10 bolts + nuts

If you mounted all parts on the printer take care before first homing! You may have to adjust the two z-screws on the linear carriage of z-axis so the nozzle doesn't crash on the heated bed, because it comes slightly lower with this carriage

The layout of the small hotend PCB is:

• HOTEND = Heating Catridge
• FAN2 = Coldend/Heatbreak Axialfan
• FAN0 = Partcooling (Radial-)Fan
• T0 = T0-Sensor (Thermistor)

Do not unplug a fan when the printer is turned on or do not turn the printer on when a fan is not plugged in you may risk damage to a transistor on the mother PCB!

Latest Changes (see full changelog in summary.pdf):

• 13.06.2020:

  • Axialfan adapter for print part cooling with an axialfan (user wish)
  • Alternative Fanduct (B) with different fan orientation in case your radialfan tends to vibrate in the way its mounted with Fanduct (A) - To use it an additional mount is necessary
  • Optimization of the fanduct design / inner flow channels for better outlet stream conditions
  • Adaption of the fanduct support in terms of thinner walls for less waste material
  • Revised e3d v6 cover plate with slightly bigger air in- and outlet for better heatsink cooling
  • Adaption of the BOM & addition of part lists for v6 hotend configurations
  • Adaption / optimization of the necessary bolt lengths for threaded insert parts (less weight)
  • Slight change of the PCB mount at the Carriage to reduce the fracture susceptibility
  • Addition of a e3d v6 VOLCANO carrier plate
  • Firmware update

• 20.06.2020:

  • Increase of tolerance oversize of the hex nut recesses by another +0.1mm
  • Bugfix: Missing Part vp 02_Extruder_Dragchain_Mount.stl added to 03_Various_Parts

• 06.07.2020:

  • Firmware update (pause function, M600, BLTouch settings improvement, …)
  • Minor tolerance change for cover-plates and carrier-plates heatsink groove mount

• 16.08.2020: Firmware update to Marlin 2.0.6

• 14.07.2022: .tar folder added containing all 3D-STEP models of this project (single parts)