Blackbox Mechanical Assembly: 17. FDM Tool Assembly

Written By: John Gilbert (and one other contributor)
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User-Contributed Guide

User-Contributed Guide

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    • The FDM (Fused Deposition Modeling) tool assembly is composed of a filament feeder and a commercial hotend such as the DICE V2.

    • Other tools can be used with appropriate modifications applied to accommodate their geometry.

    • NOTE: The terms Tool, Toolhead, and Direct Tool all refer to the same component. An FDM Tool is a specific Tool component.

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  2. Printing tolerances are very important, particularly with tool_head_part03. Perform the following checks to ensure smooth assembly. Ream to 4mm for proper heat-set insert clearance. Measurement should equal 47.5mm (significantly less can cause issues). Material shrinkage may need to be accounted for. Avoid horizontal expansion (AKA XY compensation) if possible.

    • Printing tolerances are very important, particularly with tool_head_part03. Perform the following checks to ensure smooth assembly.

    • Ream to 4mm for proper heat-set insert clearance.

    • Measurement should equal 47.5mm (significantly less can cause issues). Material shrinkage may need to be accounted for. Avoid horizontal expansion (AKA XY compensation) if possible.

    • Ream to 8mm

    • Ream to 3mm

    • This wall must be perpendicular to the top of the parts. It is highly recommended that you surface sand this part just enough to dull the layer lines to avoid alignment issues.

    • Ream to 4mm. These bores hold PTFE tube for filament constraint.

    • Ream to 2mm.

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  3. Install (7) M3x5 heatset inserts into Print_ToolHead_Part03 as marked in Red. Install (1) M3x4 heatset insert into Print_ToolHead_Part03 as marked in Blue. Install (1) heatset bowden coupling into Print_ToolHead_Part03 as marked in Green. (See heatset insert supplement for best practices)

    • Install (7) M3x5 heatset inserts into Print_ToolHead_Part03 as marked in Red.

    • Install (1) M3x4 heatset insert into Print_ToolHead_Part03 as marked in Blue.

    • Install (1) heatset bowden coupling into Print_ToolHead_Part03 as marked in Green. (See heatset insert supplement for best practices)

    • Fit (1) 5x8x2.5mm bearing from Bondtech_DriveGear_Driver into base of print as shown.

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  4. If your Bondtech Driver gear came pre-assembled with a standard Bondtech gear, you will need to remove it from the shaft in order to install the printed drive gear (Print_51TGearTool). Measure and record the distance shown in Blue. Mechanically remove the Bondtech gear from the shaft. This can be achieved with an arbor press, or by cutting away the gear. Do not melt or otherwise heat the gear. The finely splined teeth on the shaft must be clean in order to reliably secure your printed part.

    • If your Bondtech Driver gear came pre-assembled with a standard Bondtech gear, you will need to remove it from the shaft in order to install the printed drive gear (Print_51TGearTool).

    • Measure and record the distance shown in Blue. Mechanically remove the Bondtech gear from the shaft. This can be achieved with an arbor press, or by cutting away the gear. Do not melt or otherwise heat the gear. The finely splined teeth on the shaft must be clean in order to reliably secure your printed part.

    • Using a suitable driver, or press, install Print_51GearTool on shaft until the distance shown in Blue is restored.

    • NOTE: The printed gear should have a similar resistance to installation as the Bondtech gear had during removal. A loose fit will result in premature extruder failure.

    • Fit Bondtech_DriveGear_Driver assembly into previously installed bearing. Adjust the position of the knurled gear so that the filament path is in-line with the bore of the printed part (marked in Red).

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  5. Slide (1) 3x21mm linear shaft through the upper holes in printed part while capturing Bondtech_DriveGear_Idler as shown. Center the shaft in the latch. Fit Drive Latch into place as shown. Drive 3x22mm linear shaft through pivot point marked in Red. Center the shaft in the bore.

    • Slide (1) 3x21mm linear shaft through the upper holes in printed part while capturing Bondtech_DriveGear_Idler as shown. Center the shaft in the latch.

    • Fit Drive Latch into place as shown. Drive 3x22mm linear shaft through pivot point marked in Red. Center the shaft in the bore.

    • Install (1) 6x9mm spring into latch bore and gently secure with (1) M3x14mm fastener.

    • If using a Bondtech thumbscrew, the overall length of the threads will need to be reduced to fit properly.

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  6. Press remaining 5x8x2.5mm bearing into bore of Print_ToolHead_part02 as marked in Red. Slide (2) 5x4mm magnets into bores of Print_ToolHead_part03 as marked in Blue.

    • Press remaining 5x8x2.5mm bearing into bore of Print_ToolHead_part02 as marked in Red.

    • Slide (2) 5x4mm magnets into bores of Print_ToolHead_part03 as marked in Blue.

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  7. Seat ToolHead Part02 & ToolHead Part03 into position as shown. Insert tube retainer into the heatset Bowden coupling marked in Red. Insert (2) 8mm ball bearings into ToolHead_part01 as marked in Blue.

    • Seat ToolHead Part02 & ToolHead Part03 into position as shown.

    • Insert tube retainer into the heatset Bowden coupling marked in Red.

    • Insert (2) 8mm ball bearings into ToolHead_part01 as marked in Blue.

    • NOTE: ToolHead_part01 is either printed OR CNC machined. See build sheet supplement for details.

    • Fit printed or machined ToolHead_Part01 to assembly using (4) M3x16 countersunk fasteners.

    • The upper left fastener as oriented in the photo is threaded directly into the plastic body. Hole should be sized to 2.5mm to facilitate trouble-free installation.

    • NOTE: After tightening, the steel balls should have zero movement in any direction.

    • NOTE: Turn the drive gear by hand with the hinge lightly engaged. Motion should be smooth with no significant resistance during rotation. Disassemble and re-align as necessary.

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  8. Cut and install a short lenth of 4mm O.D. bowden tube to act as additional filament constraint from the outlet of the drive gears to the inlet of the heat break. For threaded tool-coolers with V6 titanium heat breaks, use 12.5mm. For smooth tool-coolers with kraken heat breaks use, 14.5mm.

    • Cut and install a short lenth of 4mm O.D. bowden tube to act as additional filament constraint from the outlet of the drive gears to the inlet of the heat break.

    • For threaded tool-coolers with V6 titanium heat breaks, use 12.5mm. For smooth tool-coolers with kraken heat breaks use, 14.5mm.

    • Secure Print_ToolHead_Part05 between latch screw and spring. This will be used to retain the heater and thermistor wiring.

    • Note: There is a channel modeled into ToolHead_Part04 for use with a small zip-tie to support the bowden feeder tube after installation.

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  9. Ream to 5mm. Press (1) 5x4mm magnet into bore. This magnet must be flush or past-flush with the surface of the cooler. Magnet orientation matters! This magnet must attract to the magnet installed in the idle tool cooler. If your cooler block is not already tapped, tap M3x0.5mm threads into the 2 holes that will secure the heat break.

    • Ream to 5mm. Press (1) 5x4mm magnet into bore. This magnet must be flush or past-flush with the surface of the cooler.

    • Magnet orientation matters! This magnet must attract to the magnet installed in the idle tool cooler.

    • If your cooler block is not already tapped, tap M3x0.5mm threads into the 2 holes that will secure the heat break.

    • Loosely attach the CNC Toolcooler to the direct tool assembly using M3x20 Button Head Cap Screws at the locations marked in Green. NOTE: Shown here are Socket Head Cap Screws. These are now deprecated.

    • NOTE: The final tightening will be performed later in assembly.

    • If using kracken heat break: Apply thermal coating and secure the heat brake inlet flush with the top of the tool cooler (facing the tool). Do so using (2) M3x3mm set screws.

    • If using threaded heat break: The tool cooler is threaded to the correct installation depth. Apply thermal coating until sufficient torque is reached. Do not overtorque!

    • NOTE: Follow the manufacturers assembly guide for your hot end. Shown here is a DICE V2 for reference.

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  10. Fit Print_ToolHead_Part04 as shown. Secure Part04 using:

    • Fit Print_ToolHead_Part04 as shown.

    • Secure Part04 using:

    • (1) M3x8mm SHCS

    • (1) M3x6 Countersunk Flathead Fastener

    • Temporarily install (1) M3x3mm set screw for use in securing the other end of the stainless steel wire guide.

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    • Repeat steps 2-9 for each additional FDM tool that will be fitted to the printer.

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  12. Edit
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John Gilbert

Member since: 06/09/2020

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