UPDATE 9.6.2022
I've fixed some tolerances of the duct so it fits easier into the base part. Also, I've noticed some aluminium carriage plates are even thicker then 3.1mm (because of a rough surface painting). I've added the base parts for carriage plates that are 3.3mm thick (best is to measure your plate on the printer with a calliper before choosing the right version to print).

OVERVIEW

This is a FULL DIRECT DRIVE (NO BOWDEN NEEDED!) for the E3D v6 and BMG extruder. The mount fits the standard carrier found at TEVO, CREALITY, and many other printers. I've tested it only on a TEVO Tornado and Ender3, but it should fit on any printer with the same carrier - see attached photo.

The following guidelines were considered when designing this extruder mount:

• it should be a full all metal direct drive (with no bowden at all)
• reduced cloging
• optimized airflow under the nozzle for good bridging
• reduced airflow to the heating block
• a good cable management solution
• accessible nozzle for an easy nozzle replacement
• easy attachable mount to the carrier

A CFD (Computational fluid dynamics) analysis was done to optimize the airflow in the Fanduct. The "water test" shows the concentrated airflow under the nozzle --> https://youtu.be/EFtvNRnnMN0

STEP FILES ARE INCLUDED IN ZIP FILE

AVAILABLE VARIANTS

1. E3Dv6 CLIP ON version (easier to mount and dismount, uses 1 screw)
2. E3Dv6 FIXED version (more fixed version, uses 3 screws)
3. Volcano CLIP ON version (easier to mount and dismount, uses 1 screw)
4. Volcano FIXED version (more fixed version, uses 3 screws)

The CLIPON versions are older version and are in a zip folder.

Use the 2.6mm version of the base for carrier plates that are approx. 2.6mm thick and the 3.1mm version for thicker carrier plates (most printers have 2.6mm --> 2.5mm thick sheet + 0.1mm paint).

The DUCT can be printed AS ONE part OR it can be printed in THREE parts (the body part, the left and the right fang). The parts can then be glued together. This is meant for easier printing, especially if you'd wish to print the fangs with ABS, ASA, PC or any other heat resistant material (printing the whole duct with ABS is quite a challenge). The fangs can deform if printed with PLA since they're positioned just around 1mm away from the heatbed.

Comments and critics are appreciated! Please write in comments if you've tried this on a different printer than TEVO Tornado, Ender3 or CR10 . There are a lot of parts with a lot of updates and version. I hope I haven't made a mistake when exporting them. However, If anything doesn't come together please write me a comment or a private msg. Thanks!

HINTS AND RECOMMENDATIONS

If you have a printer with a large build volume (like 30x30cm) and only one Z axis the first few layers won't be that good with this extruder. So I recommend to use the extruder on printers with TWO Z AXIS. I've manually added an additional Z axis and a stepper motor on the TEVO Tornado.

DON'T FORGET TO CHECK IF THE HOMING LOCATION IS INSIDE YOUR BUILD VOLUME. OTHERWISE, YOU SHOULD REPOSITION YOUR LIMIT SWITCHES FOR X AND Y.

PLEASE ADJUST THE Z LIMIT SWITCH BEFORE FIRST PRINT!!!

The nozzle height can be adjusted (around +-1mm) with repositioning the BMG extruder before you mount the stepper motor on.

IF THE STEPPER MOTOR IS RUNNING IN THE WRONG DIRECTION YOU'LL HAVE TO INVERT THE STEPPER DIRECTION IN THE MARLIN FIRMWARE (the BMG extruder runs in the opposite direction than most of other extruders)!!! There are already alot tutorials out there on how to do that, just google something like: "How to invert the stepper direction in marlin".

For good quality prints and to avoid clogging due to retraction don't forget to LOWER YOUR RETRACTION DISTANCE AND SPEED FOR THE DIRECT DRIVE (0.5mm-1.8mm and 20-40mm/s)!

When printing the fan duct, don't forget to put supports to "from bed only". Also, for printing the part "BODY.stl" no supports are neceassary. However, if you do use supports on that part, check that they're not in places, where you won't be able to remove them after the print is done.

Print with at least 70% INFILL for best results!

BLTouch offset from the nozzle is 36mm in x and 9.5mm in y direction.

ALL PARTS CAN BE PURCHASED AT OUR STORE:

https://craftrum.eu/product-category/3d-printing-accessories/
https://craftrum.eu/product/craftrums-direct-drive-mount/

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