Hypercube BMG E3Dv6 toolhead

Summary

The compact BMG+E3Dv6+BLTouch toolhead for Hypercube.

• The motor is turned backwards to save space in front and move the mass closer to the axis.
• The extruder and heatsink have their own attachment points.
• Nothing is mounted on the back of the carriage.
• Tunable zero-Y offset BLTouch (+22, 0).
• Cablechain-friendly toolhead.
• Integrated XMIN endstop.
• Easy print without any supports.
• 4010 heatsink fan and single 4020 part cooling blower.

Dimensions

60x80x135mm
382g

The Gap

Because the BMG and heatsink no more directly attached to each other there is a 20mm gap between them. This distance must be connected with PTFE tube. But I think this unused space is more of a feature than a bug. This is a perfect place to mount an ADXL or/and the filament width sensor! I don't have any of these but I'll definitely get into it later. P.S. Not the filament end sensor. Just don't. This won't work.

Printing

I printed mine entirely from ABS with 4-6 walls and 25-30% infill. ASA will work too. Use PETG only if you don't plan to work with the ABS and PA in the heated chamber.

Assembling

To assemble it you need some M3 heatsets and various M3 screws. The longest ones are for the heatsink and BMG, the others is less critical.

BOM:
- M3x40 x6
- M3x15 x6
- M3x20 x3
- M3 heatsets x15
- 4010 fan
- 4020 blower
- M2,5x10 (for endstop)

TBH I'm reusing an old Soviet МП9 microswitch from 1979 (distant Soviet march intencifies) as endstop but you just need to make the holes in the toolhead base for your particular switch and solder the wires directly to it. If you are into DIY electronics you are definitely got some switches that less than 25mm height - use any of them and don't forget the 100nF capacitor. 

STEP file is provided. Leave a comment for help.

TODO

• Try to make and use the filament width sensor that can't be closer to the hotend than now.
• Fanduct testing. I haven't used any CFD modelling yet so I need to try if my funduct delivers its maximum airflow to the part. - Cooling is OK for PLA
• I prefer ABS more then PLA and even PETG so I dont need too much cooling but for these materials may be better to mount the second 4020 blower to the other side of the carriage.
• Try to catch the InputShaping parameters and see if there is some odd wobbles. Strengthen more if there are any. - Need to update from 2.1.2.2 Marlin with IS issues
• See if my BLtouch will melts. Seriously, its only 22mm away from the nozzle. Try to use the stone wool with aluminum tape to stay safe. - BLTouch is OK with 250° nozzle
• Try to make the retraction stress print to verify the decent airflow around the heatsink. - No clogging. OK