Prusa i3 Dual Direct Extruder E3D hotend

Dual direct extruder for Prusa i3 with E3D V5 hotend.

Key features:

• Bi-delta wing shaped X carriage structure resulted in a lightweight design with high X rigidity.
• Symmetric design with minimum bending momentum load on X axis.shaft.
• Relaxed YZ constrain to decouple X axis motion with YZ plane.
• Robust cooling mount with E3D fan shroud and blower cooling nozzle.
• locking lever on extruder arm for easy filament handling
• easily accessible filament path
• belt clamp with tensioning capability

BOM

Extruder

• 2pcs MK7 extruder gear
• 2pcs spring
• 2pcs 624ZZ bearing
• 2pcs NEMA17 stepper
• 2pcs E3D V5 hotend, aka, long distance version

Cooling

• 5015s.blower fan, 12v, 52x52x15mm
• 2pcs 40mmX10mm 12v fan

Linear motion

• 3pcs LM8UU linear bearing
• 2pcs U shape pin made from paper clip pin for top LM8UU mount

Fasteners

• stepper motor 6pcs M3X20 socket head, 2pcs M3X8 countersunk flat head
• E3D clamping: 4pcs M3X20 or M3X25
• extruder spring tensioner: 2pcs M3X16
• extruder locking lever 2pcs M3X16
• extruder bearing: 2pcs M4X16
• 40mm fan mount: 10pcs M3X16
• 50mm blower bottom mount: 1pc M3X25
• belt clamp/tensioner 4pcs M3X10 or longer as needed
• M3 nuts and washers as needed

Build:

The complete build plate file: dual_direct_extruder_e3d_all_parts.stl

All parts have been designed for easy printing with minimum or no support. Fan shroud mounting holes can be M3 tapped for mounting without nut.

update:

Video: https://youtu.be/QD0Btv66SBs