A link to these files can be found on my Thingiverse and GrabCAD pages.
This new mount assembly was designed to restore full use of the CR-10/CR-10S build area. I was not thrilled with the previous design which eliminated almost 15-20 mm in X and Y so I went back to re-design this unit to fit as close to the stock CR-10 extruder assembly as possible to re-gain this area back. The Z-Axis will also improve as the long E3D hotend will be closer to the bottom of the X-Axis carriage as compared to the stock assembly.
I have designed a 40mm fan mount to accommodate the Noctua 40mm Fan (NF-A4x10 FLX). The Noctua fan reduced the ambient noise on the CR-10S from around 49-51 dB to around 39-40 dB. It fits snug enough, but is still free to rotate slightly around the E3D heatsink.
I printed this in NylonX for its flexibility, but I believe all materials should work as well, but I have not tested them.
Thanks to Sean for the Noctua 40mm fan shroud GrabCAD model and to JuanCR for the E3D V6 GrabCAD model!
Only Parts/Hardware needed
Extruder mount screws for Bondtech assembly (should be included in kit)
2X M4x0.7mm x 22mm long screws for the blower fan mount
50mm x 15mm Blower Fans
ABL Capacitive Sensor
Small Nema 17 Stepper Motor
Mount the Bondtech Extruder Carriage part to the CR-10 X-axis carriage first. Then install the blower fan, blower fan duct, and angle brace next using the two M4 screws. This will give more room to install these components without the stepper motor getting in the way. Last step is to install the stepper motor and BondTech extruder on the mount to complete the setup. Make sure to orient the heat block so that the nozzle is pointing closer to the front of the mount and thermistor/heater cartridge wires are exiting toward the bondtech assembly side
0.2mm - 0.25mm
10% - 20%
Suggested Materials (High Temp Resistant):
PETG (Material I chose)
It is recommended to use rafts on both parts for this assembly. The dimensions are critical for these parts so preventing any warp while printing is required.
I was able to successfully print the Extruder Carriage without supports anywhere, but I would suggest to add at least 4 top and bottom layers for the section that the stepper motor mounts for added rigidity and flatness.
On the Blower Fan Mount, I used supports only under the first portion of the duct to ensure the remaining overhang layers would print correctly, but depending on layer height and speeds, the results could vary.
Marlin Firmware Settings for ABL Sensor Position
X_PROBE_OFFSET_FROM_EXTRUDER 0 // X offset: -left +right [of the nozzle]
Y_PROBE_OFFSET_FROM_EXTRUDER -42 // Y offset: -front +behind [the nozzle]
Z_PROBE_OFFSET_FROM_EXTRUDER 0 // Z offset: -below +above [the nozzle]
// Set the boundaries for probing (where the probe can reach).
How I Designed This
I decided to go back to step one in determining where the best placement for this extruder assembly would be so that I could reclaim the 300 sq. mm build area back. The obvious choice would be to place the assembly so the E3D hotend would be in as close as the stock location for the CR-10 as possible. The challenges are since I will use the Direct Extruder setup, the stepper motor must be raised higher than the carriage in order to bring that long E3D hotend as close to the bottom of the X-Axis carriage as possible.
Factors that needed to be verified were clearance of the extruder motor when it hits the X-Axis endstop bracket, and if the higher Center of Gravity of the components caused any issues with print quality.