Gravitron : Orbiter 1.5/2.0/2.5 adapter

Gravitron : Orbiter 1.5/2.0/2.5 adapter

The Orbiter is a wonderful extruder. Making an adapter for it to fit the i3 Mega/Mega-S series with original X carriage is a great way to further enhance on this already very capable printer.
It's the easiest and most effective mod one could do to this printer to get Direct-Feed and print flexibles without hassles.

Notes : 

• The Mega-S can print flexibles out-of-the-box thanks to its Titan-inspired Bowden-Feed extruder.
• Designed with Mega and Mega-S in mind, it may work with other models from this series sharing the same hotend carriage design, as Mega-X and Mega-Pro do.
• Mega-SE and Mega-Zero don't share the same design, this adapter plate won't probably work on these. If I'm wrong, please let me know ! :)
• Due to the way the older i3 Mega series frame is designed, print volume is slightly reduced in Z.

A step-by-step assembly instruction PDF document is available here to download.

Important information before printing

The hex/square nut version parts have "closed" holes at the extruder mounting points(0.3mm thick) , right before the nut locations. This is done by design to force the slicer to add a single layer bridge so the upper layer is printed as it should.
Once the part is printed and has cooled down, you can simply poke through this sacrificial layer using a drill bit, a screwdriver, or a screw.

Printing instructions

Althouth PLA may work (I used a PLA prototype for a long time before switching to ABS), I'd suggest printing it in PETG/PCTG if you don't enclose your printer.
Should you enclose it, print this adapter in ABS/ASA or whichever temp-resistant material matching your own use.

3 perimeters, 25% infill (cross-hatch, gyroid, or honeycomb/3D honeycomb pattern preferred).

Required parts

• 2 M3x8 or M3x10 screws to mount the extruder on the adapter
• 2 M3x8 screws to further secure the adapter to the hotend cage (outer front edge, closest to the LCD).
• 2 M3 hex nuts OR 2 M3 heat-set inserts (height : 4mm) OR 2 M3 square nuts.  These go with the M3x8/M3x10 screws to mount the extruder on the adapter.
• 4 M3x12 or M3x16  screws to lock the adapter and the hotend in place to their respective locations
• A piece of PTFE tube. Length will vary depending on your hotend.

HISTORY :

• 2025/06/17 : V3 release
  • Complete redesign
  • Added square nuts as available fastening solution in addition to inserts and hex nuts
  • Added motor support fixtures.
  • Added in-depth PDF assembly guide.
• 2023/03/30 : V1 release
  • Adapter plates for Orbiter 1.5 added
  • Slight design changes
• 2022/03/06 : adapter plates for Orbiter 2.0 created. Prototyping.