The Copernico Extruder

I wanted to try a large gear extruder for my Trident and - while Galieo 2 may have been the easy choice - I did not want to buy another Galileo set, especially since the new version is completely incompatible with the old one I have (yes I may be a little salty about that). I did find a very interesting project from user nhchiu however due to the space occupied by the two large gears adding two filament sensors is very difficult and is not compatible with most toolhead boards. Therefore, I decided to design my own extruder. The design is inspired by the Galileo 2 extruder (hence the name) but it is lighter (only about 10g over the standard clockwork 2) and much cheaper since it uses HGX lite gears. Specifically, it uses a single HGX gear plus a bearing to avoid gear alignment problems (see MirageC video for details). It is compatible with the sb2209 family of toolhead boards and possibly all other toolheads since the space available for it is slightly larger than the space available in a standard clockwork 2 extruder. It also natively supports 2 filament sensors and the FilamATrix filament cutter system (you need the short arm for clockwork 2).

This is only a beta version and may be subjected to changes, if you want to try it and give me some feedback I will appreciate it a lot. I will provide the step file once the design is finalized.

UPDATE 12/07/2025

• Improved fit for the ECAS04 and added more space for the PTFE tube
• Added some locking features to the gearbox and the main body for ease of alignment
• Bom was slightly simplified reducing the number of different bolts needed
• Minor tolerance adjustments
• Finally I managed to finish the detailed build guide

If you printed the older version it is recommended to reprint the main body front, all other parts may remain unchanged if you did not encounter problems with them. 
I tried printing TPU and the extruder worked flawlessly but I still have other tests to do before being sure it will work reliably.

UPDATE 15/07/2025

• Added more options for the main body (single sensor and no sensor no filamatrix)
• Added supporting arms with the standard pattern for drag chain (2 and 3 holes)

I did not have time to test these new parts thoroughly, they should work as intended but if you encounter problems let me know.
 

UPDATE 09/11/2025

• editable model now available

I printed around 10 kg of filament with it without any maintenance or cleaning, and didn't encounter a single problem or jam. After disassembly, there was no visible or abnormal wear. I'm happy with the design, and I think it will become the standard extruder for my Trident. Sadly, I don't have time to design a version compatible with HGX 2.0, so I've uploaded the CAD files. If you want to try improving it, you are more than welcome.

BOM:
1     HGX lite gear set 
1     NEMA 14 36mm round stepper motor
1     MR148 bearing (14x8x4 mm)
1     4x24 mm steel pin
1     ECAS 4mm fitting
2    5.5 mm steel bearing
2    D2FC microswitch
5    M2x10 SHCS  
1     M3x6 SHCS
1     M3x8 SHCS
3     M3x10 SHCS
2     M3x20 SHCS
4     M3x25 SHCS
1      M3x35 SHCS
2     M3x8 BHCS
2     M3x6 FHCS
12    M3x4 insert

All parts should be printed in ABS using Voron standard printing guidelines, with no supports needed.