This is the successor to ProtoXtruder. With the new gears from the HGX 2.0 Extruder (affiliate link), the design becomes thinner and lighter while preserving the benefits of the larger gears.

Although it is named ProtoXtruder 2.0, it's not a direct upgrade from the previous design. There isn't much you can reuse in the BOM.

Refer to the drawing below for dimensions and compatibility with your printer. The mounting holes are compatible with the Sherpa Mini Extruder.

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• High gear reduction ratios (44:10, 37:17).
• Large extrusion gears (18 mm diameter) providing a large filament contact area.
• Oblique/twirling hobbed teeth for improved filament grip and consistent flow.*
• Compact and lightweight. All printed parts can be produced in about one hour.
• Variants for different Bowden tube retainers.
• Low profile and low center of mass.
• Optional support for a toolhead filament sensor.

This is a rough reference; the parts were not printed in identical materials or with identical print profiles.

The CNC Vz-HextrudORT I received is from early batches. Later versions added more cutouts, so newer ones are likely lighter.

From left to right:

• Oblique Tooth HGX 2.0 Extruder Gear Kit (this or this) (both are affiliate links). (I'm not certain what's included in the gear kit; I'll update this as I receive confirmation or feedback.)
  • MR63ZZ bearings × 6
  • 3 mm shaft (18 mm length) × 1 (16–18 mm may work)
  • 3 mm shaft (16 mm length) × 1 (14–16 mm may work)
  • Large extrusion gear (with oblique teeth) × 2
  • Reduction gear × 1
  • Thumb screw and tensioner spring
• Fasteners:
  • M3 × 8 mm BHCS × 1
  • M3 × 16 mm SHCS × 3
  • M3 × 20 mm SHCS × 1
  • Heat-set inserts (Voron size — M3 × D5 × H4) × 3
• NEMA14 36 mm round pancake motor with 10T gear (8T should be compatible)

Use at least 3 perimeters and 40% infill. ABS or ASA recommended.

All STL files are oriented for printing; no supports required.

It will need some bridging.

1. Install M3 heat-set inserts.

   

2. Insert the MR63 bearings into the extrusion gears (two per gear).

   

3. Assemble the extruder using the fasteners.

   Note: the M3 × 16 SHCS inserted from the motor side threads into plastic - do not overtighten. Tighten only until the screw head is flush with the printed part.

   

4. (Optional) Add the Bowden tube retainer of your choice.

   Remove the bottom half of the ECAS04 (the black plastic/rubber parts).

   

Use in conjunction with this Toolhead Filament Sensor for ProtoXtruder 2.0

For Klipper firmware:

[extruder]
rotation_distance: 53.494165  # Re-calibrate your own value
gear_ratio: 44:10, 37:17

You might need to invert the dir_pin of the extruder.

• Add support for toolhead filament sensor

• Update to match the pin length of the gear kit.

• Initial release

Designing and testing an extruder takes a lot of time and many iterations.

Thanks to Polymaker for sponsoring the filament used to print many prototypes.

Also thanks to Haldis / HS3DPrinter for sending me an HGX 2.0 extruder so I could design with their new gears. Their products are available on their website and AliExpress (affiliate link).

• The design is inspired by Sherpa Mini Extruder from Annex Engineering