IN DEVELOPMENT BigBox Dual X-Carriages (Bowden)

Discussion in 'Guides, Mods, and Upgrades' started by Greg Holloway, Jan 31, 2017.

  1. Greg Holloway

    Greg Holloway Administrator
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    bigbox_idex_bowden.png

    I have been working on a Bowden IDEX design for a few weeks and am ready to let is loose into the wild. I was never fully happy with the Direct IDEX design due to the loss of build volume and the lack of a dump zone.

    This new design is fully compatible with all versions of BigBox. There is a minimal loss in X of around 25mm, but you still retain the use of the dumpzone. There is also no need to modify the frame.

    The files are available from thingiverse | https://www.thingiverse.com/thing:2073946

    I have included the S3D .FFF File, a precomfiled RC8 .HEX, a control script for OctoPrint to add filament load / unload functions and of course all the .STL files correctly orientated and chamfered for best printings.

    scripts.jpg

    Requirements (additional).

    2 x NEMA 11 Stepper Motors. (You'll need an extra 1700mm Cable. I have a few in stock, if you are building this upgrade and purchase parts from E3D add a note to the order that you would like a motor cable).
    2 x LM8LUU Bearings.
    2 x F604ZZ Bearings.
    8 x M2.5 8mm Socket Cap Screw.
    2 x 20mm M4 Grub Screws.
    2 x 8mm M4 Grub Screws.
    4 x 45mm M3 Socket Cap Screws.
    2 x 16T GT2 Pulleys
    20 x GT2 belt (2 Meters).
    10 x PTFE Tube (1 Meter).
    2 x 460mm 8mm Ground & Hardened Shafts (cut down original BigBox 484mm Rods).
    1 x Endstop (those are not the correct ones but if you put a note in the order that it is for a BigBox we will make sure you get the correct endstop).
    1 x Blow Fan (If you mention it is for the BigBox and ask that they speak to me I'll make sure you get the fan).
    1 x Stepper Driver (These are the same A4988 Drivers but in a different design).

    If you are upgrading from a Pro BigBox you'll also need a Hotend and PT100 Amplifier board and matching cable (ask for the cable when you order)!

    When printing the parts you'll also need this | https://www.thingiverse.com/thing:1531536 and an extra X-Carriage belt tensioner.

    I would also recommend this too | https://www.thingiverse.com/thing:1755929

    I am sure there are a few minor things I have overlooked. I will update as required.

    2017-01-31 09.57.14.jpg

    ASSEMBLY NOTES

    • Do not refit the rubber o'rings into the X-Carriages, they are not required. Any offset in Z in managed via the M218 command.
     

    Attached Files:

    #1 Greg Holloway, Jan 31, 2017
    Last edited: Feb 23, 2017
  2. Miasmictruth

    Miasmictruth Well-Known Member

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    Looks great, what's the longest print you have tried, I thought I remember hearing people over heating the nema 14's
     
  3. Greg Holloway

    Greg Holloway Administrator
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    About 17 hours. If the steppers are correctly tuned they will be fine. There is very little mass so I have them turned down low. I am also using TMC2100 based drivers. I am testing them at the moment with a view to stocking them. So far I am very impressed.
     
  4. eca

    eca Well-Known Member

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    Would something like this work with this system as well? With a little tweaking of course.
    https://zesty.tech/

    I know you want to sell the BigBox extruders, but this just looks really interesting.
     
    #4 eca, Jan 31, 2017
    Last edited: Jan 31, 2017
  5. Greg Holloway

    Greg Holloway Administrator
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    Yes of course. You'll need to model your own mounting plate for it all to fit, but there's no reason why it won't work.
     
  6. Miasmictruth

    Miasmictruth Well-Known Member

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    Sounds good is that the drivers on the Duet? Just received my Duet last night but haven't had a chance to dig in yet.
     
    #6 Miasmictruth, Jan 31, 2017
    Last edited: Jan 31, 2017
  7. Greg Holloway

    Greg Holloway Administrator
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    Similar series, the duet uses TMC2660.
     
  8. Miriam

    Miriam Active Member

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    Did you try printing any flexible materials with this?
    Bowden usually doesn't handle flexible materials well.
    Where is the z sensor? under the platform?
     
  9. eca

    eca Well-Known Member

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    I think he uses the Z sensor mounted on the bed. I personally would like one on each carriage. For use with the DuetWifi
     
  10. Greg Holloway

    Greg Holloway Administrator
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    I haven't and this is one of the disadvantages of a bowden system over direct drive.

    The sensor is on the bed | https://www.thingiverse.com/thing:1531536
     
  11. eca

    eca Well-Known Member

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    This is why I want to see if this will fit a Nimble from Zesty. Not sure how much space is needed on the upper part. I just sent the .stp file to the Zesty crew and see if they can modify the mounting points in the upper part of the x-carriage.
     
  12. Miasmictruth

    Miasmictruth Well-Known Member

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    Would be interesting if we could somehow turn a titan into a remotely drive extruder, that said I would probably defeat the purpose of this design :/
     
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  13. Miasmictruth

    Miasmictruth Well-Known Member

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    So torn right now, I already have one bowden printer, If I do this conversion then I will have no direct drive setup :/
     
  14. Miasmictruth

    Miasmictruth Well-Known Member

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    Is it 275 for both or just one and something like 250 for both?
     
  15. Greg Holloway

    Greg Holloway Administrator
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    275mm for both, it is possible to stretch it to 280 for both but you'll need to be surgical with the wiring.
     
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  16. Greg Holloway

    Greg Holloway Administrator
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    2017-01-31 16.30.20.jpg

    Test cubes from left and right extruders. I have resorted back to RC6 as RC8 is too buggy for IDEX.
     
  17. Spoon Unit

    Spoon Unit Well-Known Member

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    Printed at the same time by any chance?
     
  18. Greg Holloway

    Greg Holloway Administrator
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    Nope, I have been fighting with the firmware for the last few days. T0 extruder performed brilliantly, but T1 did not. Both with esxactly the same setttings. I was trying to figure out what it was, RC8 is buggy for IDEX/DUAL, and those were the cubes after I fixed it and swapped back to RC6.

    This very moment I am printing a dual benchy....

    2017-01-31 17.17.06.jpg

    It will be done in about an hour....
     
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  19. Westsidee

    Westsidee Well-Known Member

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    I got my Prusa Original I3 mk2 so I finally can rebild my bigbox 1.0 dual. Do I need any more parts? I allready have 2 Titan extruders.
     
  20. Spoon Unit

    Spoon Unit Well-Known Member

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    Alignment looks great. What's with the nozzle? Looks like a huge amount of it poking out the bottom of the sock?
     

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