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Voron V2.4 Crystal Prison


Durahl

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A Gallery of my 350 sized V2.4 Crystal Prison

The Build started out as your run of the mill end of 2021 Formbot Kit but has gradually been upgraded with higher quality Components and mostly self-designed / redesigned MODs.

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A big part of the current concept was getting rid of the unsightly Panel Clips which I've done away with by attaching the 4mm Acrylic Panels directly onto the Frame ( with 3D Printed Spacers where necessary ) using Flathead Screws with the Sides overlapping the Top and the Door overlapping the Top and Sides for practically seamless Glass Cube look - Hence the Name Crystal Prison

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The front 8mm Acrylic Door required additional CNCed Pockets for the flush mounted look of the three 90° Print in Place Hinges and recessed "Handle".

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All of the original Gantry Parts have been redesigned for a more streamlined look utilizing Ultra Low-Profile Socket Head Cap Screws.

Meanwhile the SmoothBurner named Tool Head has been reconfigured to a CPAP Design without the StealthBurner faceted look I couldn't care for.

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The overall Dimensions and weight are slightly bigger than that of a StealthBurner but cause no issues with the geometry of the Gantry - As such there's no loss in Print Volume.

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The Front Cover attaches magnetically to the rest of the Tool Head via Screws being attracted to recessed Magnets with the former also acting as registration Pins preventing the Front from shifting ( the front can only be re/moved by pulling it towards the front ). The Wiring during assembly is a Pain in the Ass as neither the LEDs nor the Connectors fit through the Channels requiring Soldering within a partially assembled Front.

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Barely visible is the Tool Head Cutter Port situated behind the Front Cover and in-between the Extruder and Part Cooling Section.

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The Cutting is done by a Type 11 Blade with the Reset Function accomplished by a 1x40mm Spring Steel Wire sandwiched between the Part Cooling Halves.

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The in the B-Idlers installed Cutting Pin made out of a decapitated M3 Screw.

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The Reverse Bowden Tube exiting out of the CPAP Tube - While not yet fully realized yet it is planned to use this feature to keep temperature sensitive Filaments like PLA cool until they've reached the Tool Head while printing them together with high Temperature Materials like ASA.

Also nicely visible is the red Filament Tension Lever for the Bondtech LGX Lite in its normal / centered position ( left being open, right being soft materials ).

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The Tool Head with the Front removed - Much of its design came from Eytecz LGX Lite Design featuring an ERCF necessary Tool Head Sensor utilizing a Washer / MicroSwitch Combo.

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New A / B-Drives for the LDO-42STH60-3004MAC (S40) "Kraken" Stepper Motors using 30T Pulleys - While not shown in these Pictures I've since had to add active Cooling Fans to them as otherweise they'd reach temperatures beyond their Insulation Class B rating. The new Drives also come with Shaft Support Bearings at the Top.

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B-Drive Side with integrated Cable Management Passthroughs routing them to the Back Extrusion Channel and to the A-Side ( covered underneath an Extrusion Channel Cover ).

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CNCed Minimal Clearance Z-Axis Belt and Cable Passthroughs.

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To the left a self-made High Temperature Silicone Nozzle Brush, in the center one of the two 8mm Bed Surface Alignment Pins, and to the right the Bed Heater Deck Panel Connector.

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A custom variant of the CarlosRodriguess ERCF-M but using my Large Servo MOD with the latter having enough force to break the Side Latch on the Original ERCF Design.

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Different View showing the Excentric CAM Wheel attached to the Servo operating a Spring-Loaded Stylus for a Springy like effect and my own Top Hat Design for the Kieraneglin Thumper Blocks.

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Underslung BigTreeTech MMB CAN Board providing maximum cooling and protection.

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CAD Model of the ERCF-M - I had initially only decided to redo the Selector portion for adding the Large Servo MOD but in the end went full retard and modelled everything.

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The CPAP Housing with the PTFE Tube being injected into it.

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The Housing houses everything and comes with the option to divert part of the Air Stream over the FANs Control Board by removing the small ( red ) Gate below the Exhaust Port.

In a surprising happenstance the Housing paired with the thicker than usual Acrylic Panel seems to provide a fair bit of Noise dampening against the CPAP 🤔

A short Video of it.

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Well, what can I say - a very talented individual. Must say this is  the cleanest printer I have ever seen. The modifications are excellently designed and well executed. I love the way the ERCF is mounted and the traditional red and black color scheme with a dash of white thrown in the mix. Very well tuned and the printed parts are amazing. 

Thank you for sharing!!!

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  • 1 month later...

Bit of an Update to my Build:

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Overall shot seemingly without much change having happened.

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Detail Shot of the new Z-Axis Belt Reduction System to combat the Gantry Sag whenever the Printer goes into Idle, and the Z-Axis Steppers are no longer being energized.
The original design is by zzp8202 but was redone to match my Design Philosophy and to address the lack of Thread Engagement and Clearances between the Parts.

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Closeup of one of the A/B Drives with the Active Stepper Motor Cooling Fan / Mount to keep Stepper Motor Temperatures in check.
The Stepper Fan Mount can be found in the MOD Section.

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Tool-free Z-Axis Belt Tensioner inspired by the Chaotic Lab CNCed ones - Will have to do another Revision of them to address some issues.

Will probably also give Tool-free A/B-Drive Belt Tensioners a shot 🤔

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  • 2 weeks later...

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