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Dual Extrusion - want it, need it, gotta have it!

Laser8302Laser8302 Posts: 170Member, 🌟 Super Member 🌟
in Modifications & Upgrades
OK so I've had quite the learning curve with my personal A5. My ultimate goal is to do this:
https://www.aliexpress.com/item/32770576556.html?storeId=1654223&spm=2114.12010615.8148356.15.717b29354fovnl

This will be simpler to implement than a full 2 nozzle hot end, or redesigning the sled to take a different heat sink/mixing extruder system. All I need to do is add a 2nd extruder, motor and filament reel.

Any thoughts? 

The only other option I think I would consider would be a "mixing" extruder like the cyclops:
https://www.aliexpress.com/item/32699836914.html?spm=a2g0o.detail.1000023.15.602d15e3bKo5gV

But again, my goal is less modification, not more. I'me sure I could make it mount to the front of the x-carriage or something if I wanted to. I'll keep everyone posted on what I end up with.
Thanked by 1Samuel Pinches

Comments

  • Laser8302Laser8302 Posts: 170Member, 🌟 Super Member 🌟
    First piece is in, the y splitter. I ordered a mini bmg extruder thinking it was going to be geared like my current bmg extruder on my printer. Whoops, it's a 1:1 ratio... you need the extra gearing on the splitter in case there's a string that doesnt get pulled out enough.

    Anyway, here's some pictures until I get it installed.



    Thanked by 2Gandy Samuel Pinches
  • Samuel PinchesSamuel Pinches Posts: 2,997Administrator
    How did this go, any luck? :smiley:
  • Laser8302Laser8302 Posts: 170Member, 🌟 Super Member 🌟
    I've been doing a lot of printing... gifts for the holidays and such. Ive mounted my extruders at the top of the gantry so far.

    I also replaced the x carriage bearings, and the motor couplers with solid couplers instead of flex type.

    Next up, y axis bearings, new heat bed, flex steel build plate and a SKR 1.3 board to run the dual extrusion.

  • KmxSoftKmxSoft Posts: 4Member
    Another option, albeit more expensive, is the Mosaic Pallette 2 which manages up to 4 filaments thru a single nozzle:


    This isn't a mixer nozzle like the cyclops, it simply physically switches the filament between spools, and filament is melted within the Pallette 2 at change intervals to create a single strand. So unlike cyclops you can't blend different colours, it's one colour or the other.

    Thanked by 1Samuel Pinches
  • Laser8302Laser8302 Posts: 170Member, 🌟 Super Member 🌟
    Thanks for the suggestion but I don't think I want to spend that much just yet.

    I've got everything back together finally! I've been using TMC2208 drivers in standalone mode, and with the SKR in uart mode they are even quieter! Even my extruder got quieter on the A4988 for some reason...

    I now need to work out the tool change g code. I want to "hammer forge" the filament before swapping it. I have decent dual drive gear extruders from trianglelab.

    I was trying the TOOLCHANGE_FILAMENT_SWAP firmware feature, but for some reason after the first swap all the extruders do is vibrate and then I have to stop the print and figure out what happened. I think I'll just use tool change scripts in the slicer.

    Here's some pictures of what I've got set up.



    Thanked by 1Samuel Pinches
  • Laser8302Laser8302 Posts: 170Member, 🌟 Super Member 🌟
    edited February 2020
    I meant to take pictures of the SKR 1.3 board I put in but I forgot...

    Still trying to figure out what slicer handles the dual extruders best. CURA would be my go-to if it hasn't been so slow on my work PC to slice things and change extruders. It's so slow that sometimes I enable and disable the extruder on our ultimaker setup that CURA crashes...

    Idea maker seems promising. It can group models quite well VS prusa slic3r where you have to position the models carefully.

    Prusa slic3r doesn't give you as much control over the tool change as I would have hoped. Maybe they updated that since 2.1.0 maybe...

    This is what I have for Start G-code (With BL touch and unified bed leveling)
    ;__________START G-CODE_________________
    G21
    G90
    M82
    M107
    G28
    G29 L1
    G29 A
    G29 J
    G92 E0
    G1 E-200 F3600
    T1
    G1 E2
    G1 X30 Y10 Z0.20 F12000
    G92 E0
    G1 F1800 X80 E25
    G1 F2400 X100 E26.5
    G92 E0
    G1 E-200 F3600
    T0
    G1 E2
    G1 X30 Y11 Z0.20 F12000
    G92 E0
    G1 F1800 X80 E25
    G1 F2400 X100 E26.5
    G92 E0

    This makes sure BOTH extruders are primed and ready to go.
    Then there's the extruder switch code:
    G92 E0
    G1 F3600 E-22.0000
    G1 F300 Z0.510
    G0 X10 Y10 F6000
    G91
    G1 F3600
    G1 E5 ;<-"ram" the filament back and forth in the heatsink to shape the tip a bit
    G1 E-5
    G1 E5
    G1 E-5
    G1 E5
    G1 E-5
    G1 E5
    G1 E-5
    G4 S3 ; Wait for the filament to cool a bit
    G1 E-200 ;Extract filament out of y split
    T1
    G1 E200 ;insert new filament
    G90

    With this setup, I think I'm FINALLY ready to try my first dual-color print. Fingers crossed I can find more time this week or next week to try.
    Thanked by 1Samuel Pinches
    Post edited by Laser8302 on
  • Samuel PinchesSamuel Pinches Posts: 2,997Administrator
    Looking good!!!!
  • Laser8302Laser8302 Posts: 170Member, 🌟 Super Member 🌟
    edited March 2020
    Started my first print and the first 3-4 tool changes went without issue. Then I got a jam in the y adapter. I think I might also need to re-calibrate my e-steps, I had to run flow at 116% to fill the model.

    In order to increase the tool change speed, I went to 1/8 steps instead of 1/16 so that I could run the filament in and out faster. I just went to 1/2 of my E-steps to get to this, I guess I should re-calibrate.

    I also needed to re-slice the model because I didn't do enough purge between colors. See below for my first attempt.


    Thanked by 1Samuel Pinches
    Post edited by Laser8302 on
  • Samuel PinchesSamuel Pinches Posts: 2,997Administrator
    Makin progress!!
  • Laser8302Laser8302 Posts: 170Member, 🌟 Super Member 🌟
    I found the picture of the SKR board installed.
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