Archetype Blackbird-Orbiter Cutter and Toolhead Sensor

May 2025 - Version 2:
Addressing an issue where after about 200+ cuts the microbowden tube starts becoming deformed due to the lateral pressure of the cutting blade.  Result was in incomplete cuts and jams in the tradrack on subsequent loads and cut tips getting stuck in the bowden tube.
- Moved cutting blade to be flush with lower mount, related lower lever/mount changes
- 1 additional heatset insert needed - added below cutting blade in lower mount to provide solid cutting surface
- Reduced entire stack height by 2mm
- Simplified routing of toolhead sensor wire

Build Notes:
- Interface between lever and upper and lower mounts needs to be sanded smooth to reduce friction which causes the lever to hang on return
- I printed the lever top with upside down with supports to have the best interface with the blade, tolerances in that area are very tight
- Lower mount still needs to be printed vertically with supports

Original:

Here's my crack a toolhead cutter and filament sensor for the Archetype toolhead with an Orbiter v2.  I'm using a dragon ace, but should be compatible with all Archetype hotend mounts, but I have no way to test.  Magnets are used to hold the cutting lever in place when not in use to avoid vibrations.  My design adds 17.5mm to the vertical height of the flat mounted orbiter.

Lower mount needs to print with supports.  All remaining parts are printable without supports.  I printed in ABS.

The activator is design to sit above Y-backers so may be a bit short (Z-axis) if you don't have backers.  The activator in the longest position works perfectly on my Voron 2.4 350 with max lever movement occurring at X:7mm and contact occurs at about X:36mm.  I lose about 45mm x 10mm at the back of build plate, which could probably be tuned out if I cared more. 

This is one of my first designs in Fusion so it's probably a bit rough around the edges.

Modification to PAC's flat orbiter mount were adding of a hole for the metal rod to sit in and some minor cleanup.
https://www.printables.com/model/879269-archetype-flat-orbiter-mount-v2-blackbird-mjolnir

Lever was remixed from JAT's filament cutter for Orbiter, added some vertical retention at the cutting end, screw to secure the lever end and other modifications to account for rear activation and magnet retention. 

Parts
- 3 voron standard magnets (round 6mm x 3mm)
- #11 cutting blade
- 5mm metal rod 18mm long, up to 24mm will work
- 5.5mm ball bearing
- end stop sensor
- spring from pen
- 9 m3 heat set inserts
- small collection of necessary fasteners