Parts for new Hot end.JPG
Project data
Authors Matthew Olson
Completed 2018
Made? Yes
Replicated? No
Cost USD 71.39
Download Open Know How Manifest
Page data
Type Project
Keywords 3D printer modification, 3D printing, Athena II, flexible material, hot end, plastic
SDG Sustainable Development Goals SDG09 Industry innovation and infrastructure
Authors Matthew Olson
Kathy Nativi
Published 2018
License CC-BY-SA-3.0
Affiliations Michigan_Tech's_Open_Sustainability_Technology_Lab
MY4777
MTU
Language English (en)
Impact Number of views to this page. Views by admins and bots are not counted. Multiple views during the same session are counted as one. 717


This page lays out the steps required to convert your current Delta Athena II printer to have a newly designed flexible driveshaft printer, which makes printing in flexible materials a reality.

Design[edit | edit source]

The current setup on the Athena II printer is not suited for flexible materials like ninja flex. Due to the bowndeth sheath setup we mostly use stiff filaments such as PLA. The new design was based off of the desire to remove the bowden sheath from the printer and to get the same impact as a direct drive printer. Using a flexible shaft I was able to mount the motor to the Athena II's frame and still have the extruder feed directly above the print nozzle, removing the need for a long bowden sheath.

Printing[edit | edit source]

The design required that I modify the hotend, and extruder stepper motor bracket. So after some research on direct drive designs I was able to complete my new design with as little mass as possible. In the picture below is a screen shot of cura with all the parts needed for the mod fitting in one print. A total of 40g of PLA is needed to complete the print. Files can be found here, Thingiverse Link to Files

Installation[edit | edit source]

Below you will find a list of new materials required to modify the printer, followed by a list of re-purposed components from your Athena II

Description Link Price Count
Hot end bearing shaft spacer Print it! $0.01 1
Hot end bearing shaft Print it! $0.02 1
Flexible shaft sheath holder Print it! $0.10 1
Left clip Print it! $0.10 1
right clip Print it! $0.08 1
Motor Bracket Print it! $0.14 1
Hot end small plat Print it! $0.01 1
End effector Print it! $0.36 1
5mm to 8mm 3/4 long aluminum spacer Link $0.60 1
M3 x 10 screws for motor Local hardware store $0.25 4
FOREDOM FLEXSHAFT SET MOTOR MAINTENANCE KIT S-93 INNER SHAFT & S-77 OUTER SHEATH (E 12) NOVELTOOLS Link $25.75 1
Witbot MK7 Stainless Steel Extruder Drive Gear Wheel 5mm Bore for 3D Printer(Pack of 5pcs) Link $6.99 1
E3D Lite6 Full Kit - 1.75mm Universal (Direct) (12v) Link $36.99 1
Re-purposed parts from Athena II
Description Count
Nema Extruder stepper Motor 1
Bolts... 2
nuts... 2
Washers... 2
Bearing 1
RepRap Athena 1
Ethernet Cable 1

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