Dual Extruder V0.75 Assembly instructions.

12/31/2013 - bam

The V0.75 is the first release candidate for a Lulzbot TAZ compatible dual extruder tool head, which can be used to print multi-material parts. The full bill of materials, stl files and gcode, as well as the FreeCAD source files can be found here.

Ingredients:

2 fully gregs wade style extruders, these can be either our standard extruder (standard extruder assembly instructions), or our new Flexystruder for printing flexible materials (flexystruder assembly instructions).

1 Printed Dual extruder lower

1 printed flexure plate

1 printed dual extruder mount

2 M5x20 screws with cap

2 M5 heat set inserts

4 M4x20 Socket cap screws

4 M3x25 Socket cap screws

4 M3 washers

4 M3 heat set inserts

All of the non printed parts (vitamins) needed for the dual extruder assembly. Note: extra wiring and extruder components are not shown.

All of the printed parts needed to assemble the dual extruder

Step 1: Install heat set inserts.

Install 4 M3 heat set inserts into the underside of the dual extruder mount (left image below). Also install 2 M5 heat set inserts into the top of the height adjustment bracket (right image below). You can install both of these using a standard soldering iron; just place the insert on the tip and press it lightly against the printed holes. Once the tops of the inserts are flush with the surface of the part, remove the soldering iron and set the part aside to cool. The inserts hold their heat for a surprisingly long time, so use caution when handling the parts afterwards.

Step 2: Install the extruders onto the flexure plate.

Start by installing the first extruder into the back hole of the flexure plate as shown below. Make sure that the extruder is sitting on the flat shiny side of the part with the extruder motor and the budashnozzle wires facing toward the curved front. Insert 2 M4x20 bolts through the hoes in either side of the nozzle, and tighten down.

Then install the 2nd extruder with the gears facing the rounded front of the part as shown below-right.

Step 3: Assemble the dual extruder mount.

As shown below, sandwich the flexure plates with the extruders between the extruder mount (top) and the dual extruder height adjuster (bottom). Secure with 4 M3x25 screws with washers. The screws feed up through holes in the lower part and screw into the inserts in the bottom of the upper piece, sandwiching the flexure plate in between.

Tighten the 4 screws evenly to make sure a good connection is made.

Step 4: Install height adjustment screws

Screw 2 M5x20 Screws with thumbscrew caps into the M5 inserts on the underside of the dual extruder assembly. You'll use these to bend the flexure plate slightly to make sure that both nozzles are in the same XY plane parallel to the bed.

Step 6: Print awesome multi-material parts.