3D Printer: Ashtar K IDEX (Independent Dual Extrusion)

Status: verified design

Updates:

2021/07/30: design printed and mounted
2021/01/19: improved 2nd X motor mount
2021/01/15: removable/replaceable ooze prevention
2021/01/14: Ashtar M (Moving Gantry – Draft) also with IDEX option now
2021/01/13: ooze prevention at rest position added, mechanical conflict resolved
2021/01/12: starting with a first draft, one mechanical conflict to be resolved

Introduction

I have been pondering on a dual independent X axis upgrade or option for a while, but the other designs of the Ashtar Series I wanted to do first (Ashtar D and Ashtar M) those matured by now (2021/01), so I decided to get back to IDEX upgrade for Ashtar K:

For now I like to keep single 2020 V slot alu extrusion for the X beam where the X carriage rides, and route the 2nd belt above for the 2nd X carriage – and this was a quick solution as earlier version of Ashtar K had the belt routed above the alu profile so I just reused the old pieces again.

“Above routed belt” option with its pieces are weaker and ~~possibly need enforcement~~ improved the strength, so it’s a fast start – just took me 2 hours – but needs definitely some fine-tuning. ~~Alternatively the 2nd belt could be routed at the back of the X carriages, but fastening the 2nd X motor would be challenging.~~

For now I use the same code base of Ashtar K and introduce IDEX = true flag, and enhance a few existing pieces in parts.scad and optionally add those new pieces when rendering printer-ak.scad.

As I progress with this option or upgrade I update this blog-post.

Draft

Issues to Resolve

X carriage #1 belt mount conflicts mechanical with belt 2: redesign xcarriage_beltmount_2020 piece, make it shorted in Z or fasten it inside V module: resolved, shifted 2nd belt a bit Y off, and shorten xcarriage_beltmount_2020(idex=true) by 2mm.

*2nd belt slight Y offset so X belt mount #1 doesn’t touch belt #2*

“Above routed belt” pieces are weaker: enforcement required, resolved: piece strengthened (2021/01/19):
- xcarriage_short_hmount_motor_2020 which is the base piece which routes the belt within the 2020, with idex=true option provides idler holder on top
- X motor #2 is mounted on a x-mirrored version of xcarriage_hmount_motor(20,"left",idex=true) but definitely needs reinforcement, added ooze prevention in case of idex set

Nozzle drip prevention:
- using a piece of sheet metal which the nozzle moves over when in rest position left or right, first attempt done (see below)
- and/or use purge box with brush to clean nozzle after and before use
- ~~make extending “nose” detachable/replaceable as it’s expected to break or overheat otherwise entire X motors mount needs replacement~~, resolved
  - xcarriage_nose-idex-left and xcarriage_nose-idex-right with 10mm wide sheet metal insert
- how dealing with long resting hot nozzle?
  - drop temperature by 5-10°C in rest position, and heat up when in use again
  - heat creep possible weakening extending printed nose – heat insulation required attaching sheet metal

Inside and Above 2020 belt routed X motor mount, w/ removable nose with ooze prevention

Gallery

Ashtar M IDEX

And since Ashtar M (Prusa i3 Moving Gantry – Draft) shares much of the Ashtar K design it took me a few mins to add the IDEX upgrade option as well:

References

BCN3D Technology IDEX, some background info on IDEX
EnderIDEX Dual X-Axis Kit, simple upgrade for Ender 3, also with above routed belt
Rat Rig V-Cast IDEX, alu extrusion-based prefab kit

XYZ dims *

3 Dimensions Explored – 3D-Modeling & 3D-Printing