Made the frame for my one wheel! Im using 8mm thick bent steel for the main frame, as well as some CNC machined plates for holding the two sides together. Between them is the hub motor, which is a 10” 800w motor at 60v. I plan to make my own battery pack to go in one side, and Ill have electronics on the other side.
Hotend design!! this is my second shot at making a decent hotend. My goals for this are to have a large melt zone, nice heater, filament path, and thermistor packaging, while keeping it small and lightweight. I was inspired by hotends like v9 (https://www.v9hotend.com/), tricorn (http://tricornhotend.com/) and Turtle’s double barrel hotend he made for #rework (https://github.com/ProgrammerTurtle/DoubleBarrel). These all have CNC’d heater blocks and heatsinks.
My idea for this hotend is to use a supervolcano heater cartridge (likely a high wattage one from Lukes Lab), in combonation with a very light weight and compact block to have as little temperature gradient between the heater and the thermistor as possible.
You can see that idea here in Turtle’s hotend.
The heaters are extremely close to the filament path and nozzle, which means that they dont waste energy heating the rest of the block. The walls are also very thin, which means that less heat is lost into the block. Another advantage of this is that the thermistor is able to read a very accurate temperature at the nozzle. The further the thermistor is from the heater the larger the difference will be.
Total time spent: 3 hours
I spent this session polishing the design. This includes assembling everything in cad, thinking about a real life assembly process, and making a couple renders of the project.
Here you can see how the entire design comes together. The filament path is like this: Heatbreak -> Supervolcano adapter -> Nozzle. Overall really simple. You can also see how close together everything else is in this view, which includes the heater, thermistor, and filament path. You can also see how efficient the heatbreak mounting is. yay!
There are multiple things I needed to balance in the block design for this hotend.
The design is fairly simple. I started with a couple circles to give holes for the heater bore, meltzone, and thermisor to sit. I origonally planned to use an M3 pt1000 thermistor, but was told that a cartridge thermistor would have better thermal control.
I basically just extruded that upwards enough to fit the threaded part of a heatbreak, a supervolcano nozzle adapter (more on that in a sec), and a nozzle. I also added a section at the top for heatbreak stuff.
I added features to allow the pt1000 and heater to fit in, and cleaned up the cad a bit.
Here you can see something close to the final heater block design. I added holes for grubscrews to clamp the heater as well as mounting holes for the heatsink mounts.
About the supervolcano adapter. JLC does not like drilling 2mm holes 51mm long. So instead ill be using an m6 tap all the way through the part to create a 2mm hole. nice! and its cheap too. This also gives me a really nice mating surface for the nozzle so overall really helpful.
Total time spent: 6 hours
Motor Mounts
I spent this session polishing the design. This includes assembling everything in cad, thinking about a real life assembly process, and making a couple renders of the project.
Here you can see how the entire design comes together. The filament path is like this: Heatbreak -> Supervolcano adapter -> Nozzle. Overall really simple. You can also see how close together everything else is in this view, which includes the heater, thermistor, and filament path. You can also see how efficient the heatbreak mounting is. yay!
I spent this session polishing the design. This includes assembling everything in cad, thinking about a real life assembly process, and making a couple renders of the project.
Here you can see how the entire design comes together. The filament path is like this: Heatbreak -> Supervolcano adapter -> Nozzle. Overall really simple. You can also see how close together everything else is in this view, which includes the heater, thermistor, and filament path. You can also see how efficient the heatbreak mounting is. yay!
I started this project thinking that I would make the hotend air cooled. I realized pretty quickly that that wouldnt work very well for a number of reasons. If the filament path was centered in the heatsink, then there wouldnt be much of an issue with turning a decent heatsink. But since the filament path is not centered, turning it would be literally impossible. You can see here how difficult it would be to turn that.
I ended up switching to a new idea. Conduction! why have heatsink fins when you can have a big block of metal for a toolhead. ok very cool!
You can see the big block here ^^
The way the heatsink is mounted is pretty interesting IMO. I am using two SLM Titanium arms to connect the heatsink to the block. Since titanium has fairly low heat conductivity, its pretty perfect for this. The geometry also helps a lot with stopping excess heat from going into the block. You can see how everything connects together with m2 screws here.
I designed in some interesting geometry on the connector itself to try to minimise contact area between the block and the connector. it kinda looks like a castle.
Im using a standard v6 heatbreak in this hotend. It has a smooth side and a threaded side, which lets me use my fancy mounting style accurately. yay!
Total time spent: 4 hours
I started this project thinking that I would make the hotend air cooled. I realized pretty quickly that that wouldnt work very well for a number of reasons. If the filament path was centered in the heatsink, then there wouldnt be much of an issue with turning a decent heatsink. But since the filament path is not centered, turning it would be literally impossible. You can see here how difficult it would be to turn that.
I ended up switching to a new idea. Conduction! why have heatsink fins when you can have a big block of metal for a toolhead. ok very cool!
You can see the big block here ^^
The way the heatsink is mounted is pretty interesting IMO. I am using two SLM Titanium arms to connect the heatsink to the block. Since titanium has fairly low heat conductivity, its pretty perfect for this. The geometry also helps a lot with stopping excess heat from going into the block. You can see how everything connects together with m2 screws here.
I designed in some interesting geometry on the connector itself to try to minimise contact area between the block and the connector. it kinda looks like a castle.
Im using a standard v6 heatbreak in this hotend. It has a smooth side and a threaded side, which lets me use my fancy mounting style accurately. yay!
Total time spent: 4 hours
There are multiple things I needed to balance in the block design for this hotend.
The design is fairly simple. I started with a couple circles to give holes for the heater bore, meltzone, and thermisor to sit. I origonally planned to use an M3 pt1000 thermistor, but was told that a cartridge thermistor would have better thermal control.
I basically just extruded that upwards enough to fit the threaded part of a heatbreak, a supervolcano nozzle adapter (more on that in a sec), and a nozzle. I also added a section at the top for heatbreak stuff.
I added features to allow the pt1000 and heater to fit in, and cleaned up the cad a bit.
Here you can see something close to the final heater block design. I added holes for grubscrews to clamp the heater as well as mounting holes for the heatsink mounts.
About the supervolcano adapter. JLC does not like drilling 2mm holes 51mm long. So instead ill be using an m6 tap all the way through the part to create a 2mm hole. nice! and its cheap too. This also gives me a really nice mating surface for the nozzle so overall really helpful.
Total time spent: 6 hours
There are multiple things I needed to balance in the block design for this hotend.
The design is fairly simple. I started with a couple circles to give holes for the heater bore, meltzone, and thermisor to sit. I origonally planned to use an M3 pt1000 thermistor, but was told that a cartridge thermistor would have better thermal control.
I basically just extruded that upwards enough to fit the threaded part of a heatbreak, a supervolcano nozzle adapter (more on that in a sec), and a nozzle. I also added a section at the top for heatbreak stuff.
I added features to allow the pt1000 and heater to fit in, and cleaned up the cad a bit.
Here you can see something close to the final heater block design. I added holes for grubscrews to clamp the heater as well as mounting holes for the heatsink mounts.
About the supervolcano adapter. JLC does not like drilling 2mm holes 51mm long. So instead ill be using an m6 tap all the way through the part to create a 2mm hole. nice! and its cheap too. This also gives me a really nice mating surface for the nozzle so overall really helpful.
Total time spent: 6 hours
Hotend design!! this is my second shot at making a decent hotend. My goals for this are to have a large melt zone, nice heater, filament path, and thermistor packaging, while keeping it small and lightweight. I was inspired by hotends like v9 (https://www.v9hotend.com/), tricorn (http://tricornhotend.com/) and Turtle’s double barrel hotend he made for #rework (https://github.com/ProgrammerTurtle/DoubleBarrel). These all have CNC’d heater blocks and heatsinks.
My idea for this hotend is to use a supervolcano heater cartridge (likely a high wattage one from Lukes Lab), in combonation with a very light weight and compact block to have as little temperature gradient between the heater and the thermistor as possible.
You can see that idea here in Turtle’s hotend.
The heaters are extremely close to the filament path and nozzle, which means that they dont waste energy heating the rest of the block. The walls are also very thin, which means that less heat is lost into the block. Another advantage of this is that the thermistor is able to read a very accurate temperature at the nozzle. The further the thermistor is from the heater the larger the difference will be.
Total time spent: 3 hours
Hotend design!! this is my second shot at making a decent hotend. My goals for this are to have a large melt zone, nice heater, filament path, and thermistor packaging, while keeping it small and lightweight. I was inspired by hotends like v9 (https://www.v9hotend.com/), tricorn (http://tricornhotend.com/) and Turtle’s double barrel hotend he made for #rework (https://github.com/ProgrammerTurtle/DoubleBarrel). These all have CNC’d heater blocks and heatsinks.
My idea for this hotend is to use a supervolcano heater cartridge (likely a high wattage one from Lukes Lab), in combonation with a very light weight and compact block to have as little temperature gradient between the heater and the thermistor as possible.
You can see that idea here in Turtle’s hotend.
The heaters are extremely close to the filament path and nozzle, which means that they dont waste energy heating the rest of the block. The walls are also very thin, which means that less heat is lost into the block. Another advantage of this is that the thermistor is able to read a very accurate temperature at the nozzle. The further the thermistor is from the heater the larger the difference will be.
Total time spent: 3 hours