D810 2040 extruder and spool mount

A spool holder to mount on the 2040 extrusion at the top of my Zonestar D810 delta, and an associated extruder mount. This makes the spool holder and extruder much more accessible for changing filament, and shortens the Bowden tube quite a bit. The spool holder is positioned so it feeds as directly as possible into the extruder.

The top of spool holder needs to be very strong because all the torque of a 1Kg spool is applied there. It's angled at 30 degrees to reduce the torque somewhat, and so that the spool will be kept on the holder by gravity.

One extruder mount is designed for the stepper motor and extruder that I got with my printer. The other (added 15 Aug 2017) is designed for the stepper motor and extruder that came with my Diamond hotend.

The other motivation is that I'm planning on putting a Diamond 3-colour hotend on my printer; this way, I'll be able to have 3 spools and extruders on top of the printer, one on each side.

These will be usable for other deltas (or anything else with a 2040 profile). The Zonestar D810 has a 5mm acrylic plate on the top of the 2040 profile... other deltas may not, so you'll need to modify the design or add in 5mm of packing.

Spoolholder is printable on a 160mm bed.

As designed here, it's good for the front or right side of a delta. Mirror it if you want the spool to be on the left and removable from the front.

Still to come: a "universal" spool hub for spools with small holes (under 40mm) using F688ZZ bearings. Some of spools are very wide and have very small holes, so there's not enough room on the 150mm bolt for the quick-release nut.

Print Settings

Printer:

Zonestar D810

Rafts:

No

Supports:

No

Resolution:

0.2

Infill:

30%

Post-Printing

Hardware

3 or 4*8mm washers

1* M8 x150mm coachbolt

3*M3 x 10mm screws (I prefer socket head) to attach spool holder to 2040 profile

3* M3 x 10mm countersunk screws to attach D810 extruder mount

2M3 x 10mm, 1 M3 x 16mm screws to attach Diamond extruder mount

6* M3 hammer nuts (aka T-nuts)

Hot-Glue the coachbolt into the hole in the spoolholder

Put the washers between the spool holder and spool hub

Use a universal spool hub conical mount, and some kind of quick-release M8 nut

How I Designed This

OnShape.com, Public documents

The spool holder and Diamond extruder mount are here:
https://cad.onshape.com/documents/0cadcefb82ab5cdfa610e58f/w/34530a20da7b738a0ca7a1a5/e/705fb3d4217479bde70e11c6

The standard D810 extruder mount is here:

Category: 3D Printer Parts