OV5693 Nozzle Camera for the Prusa Core One

About

This is a nozzle camera mount for the Prusa Core One, which utilizes the OV5693 USB camera module. The camera is aimed between the hotend and the right side of the print fan duct. Despite the tight clearances, the extruder's full range of motion is preserved.

Compared to the popular 3DO nozzle camera, the OV5693 module used here is significantly cheaper, and more compact. It is widely available on Aliexpress for around 20 CAD, and other similar stores. Get a camera with the same PCB as mine, so that everything fits as designed. While not typically indicated, my PCB is model HBVCAM-5M2118AF76-48. I do not recommend the autofocus variant, since you need to get the camera to focus very close up. Look for one with a flex cable around 60mm as well.

There is space for an optional 3mm illumination LED. While the printer's LED strip does a decent job up close, the view gets a bit dark towards the rear of the printer. I soldered my LED to the USB connector on the camera PCB. Keep in mind that since the LED is connected directly to the USB VBUS, it will stay on as long as the camera is plugged in, regardless of printer state. I kind of like it always on though, it makes the printer look like an abandoned factory at night when everything else is turned off lmao

Printing

This mount prints as two separate parts, so some basic assembly is required. I used 3x M2.5 x 5mm machine screws, two for the mount and one for the camera PCB. Step files are provided so that you can easily resize the screw holes for whatever hardware that you have available.

Print each part as oriented, no supports are needed. I printed mine in PETG, with 100% infill and fuzzy skin enabled on the Camera Mount part. I recommend using the highest temperature filament that you have available, due to the mount's proximity to the hotend. Additionally, the camera itself gets pretty hot during use. While this is normal, it was enough to soften the prototypes that I had printed with PLA.

Assembly

1. Guide your camera's USB cable along the existing cables leading up to the extruder. There should be just enough room to fit the cable through the side cover.

1. Screw the camera PCB into the Fan Bracket. Only one screw is used, the other side of the PCB is supported by the fan bracket. Leave the camera and USB cable disconnected from the PCB for now. Solder your 3mm LED to the camera PCB, if using. Use the thinnest stranded wire that you have. Don't forget your current limiting resistor!

1. Screw the Camera Mount assembly to the Fan Bracket assembly, using your two remaining screws. Guide the wires for your LED through the loop in the Camera Mount, if using. Insert the LED into the hole next to the camera, it should slightly poke out the other end.

1. Insert the camera in into the Camera Mount. The camera is a bit of a tight fit, and it needs to be pushed in at an angle as shown below. One pushed in, the camera lens protrusion slots into the mount. This keeps the camera aligned and prevents it from moving or falling out. Guide the camera's flex cable through the retaining feature on the mount.

1. Guide the camera flex cable through the Fan Bracket. Connect it to the camera PCB, while making sure to lock the connector properly.

1. Remove the two screws from the printer's hotend fan. Line the assembled nozzle camera up to the fan, using the two pegs on the Fan Bracket to help you align it. Use those same two screws to secure everything to the extruder.

1. Connect both ends of the camera's USB cable, and verify that everything works. You may need to remove the assembled mount to adjust the focus. Turn the lens counter-clockwise to move the focal point closer to the camera, and vice-versa. Clearances with the printer's CoreXY frame and LED strip are very tight, so please make sure to manually verify that the extruder still has its full range of movement after installation.