3D Printer Modernization and Conversion
Frame: Used Ender 5 Plus's 2020 aluminum extrusion frame and electronics housing.
Kinematics: Converted the Cartesian XY kinematics for a more favorable CoreXY kinematic system using the ZeroG Mercury One.1 Project. Replaced Delrin wheels with linear rails for smoother operation and new Nema17 motors for stronger movement.
Firmware and Hardware: Replaced the stock board for a BTT SKR Mini E3 V3 with a raspberry Pi running OctoPi server software. The Ipad is running the server interface and acts as a UI for the printer. Replaced the stock Marlin Firmware for Klipper for OctoPrint and CoreXY compatibility and more customization.
Toolhead:
EVA3 toolhead with a Phaetus Rapido 2 UHF, cooled by a 4040 Noctua fan. Dual 5015 blower fans in the rear flow through 4 nozzles to cool the part. Uses the stock BL touch for bed leveling. BTT ADXL345 attached to the top connected to the Raspberry Pi via usb-c for Resonance Compensation. Custom bowden tube coupling routes to the back of the printer where the extruder is located to reduce carriage weight.
CAD and Overall Design:
While there is a lot to be desired, I have used the CAD to help with custom parts, such as the bowden tube coupler, iPad stand and front electronics cover.
In the future, I hope to use this as a basis for more upgrades, including a Toolhead Changer, Automatic Material Switcher and more. Much of the electronics are not included in the design, but I plan to make a custom electronics bay to replace the old electronics cover in the future.
Note: this project is currently in progress so a conclusion has not been written yet.
BTT: https://bigtree-tech.com/
EVA3: https://main.eva-3d.page/
Mercury One.1: https://docs.zerog.one/manual/build/mercury_eva
Creality Ender 5 Plus: https://www.creality.com/products/ender-5-plus-3d-printer
Phaetus: https://www.phaetus.com/en-us
Klipper: https://www.klipper3d.org/
OctoPrint: https://octoprint.org/
Capricorn: https://www.captubes.com/index.html
OrcaSlicer: https://www.orcaslicer.com/