Sovol SV08/max/ZERO toolhead CHC XL

Active Development Notice: This project is currently under active improvement! If you are interested in this model but want a version that is fully ready and requires no modifications, please wait a little longer. I am finalizing testing and will release the completed version soon. I would also be happy if someone could help me fix minor issues and participate in the beta test.

The stock SOVOL SV08 has a reasonably capable hotend, but like the rest of the printer, it is mediocre and lacks a durability margin. After my original hotend failed, I decided to replace it with something more performant. The CHC XL is the optimal choice in terms of price-to-performance ratio.

I considered using a pre-existing Voron-style toolhead designed for the CHC XL. However, I didn't like any of the available options. They are often complex and time-consuming to manufacture, and the final result ends up heavier than the original toolhead.

My goal was to use a minimal number of parts to achieve high performance quickly and without unnecessary cost.

Printing Instructions:

• You must print the parts from ASA, ABS, CF- or GF-reinforced variants (I used white ERYONE ASA-GF).
• Your printer must be well-calibrated. All parts should fit snugly but without excessive force.
• The air duct part is a good indicator: if it fits onto the fan well, the rest of the assembly should proceed without issues.

Print Settings:

• 5 perimeters
• 6 top and bottom solid layers
• 15% infill

Supports are only required for the part that holds the fans (refer to the attached .3mf file). The optimal print orientation for all parts can also be found in the same .3mf file.

Firmware Configuration (printer.cfg):

Due to the bed leveling sensor being relocated to the back of the mounting plate, you need to make the following adjustments in your printer.cfg:

[quad_gantry_level]
... 
points: 30,10
  30,300
  350,300
  350,10
 ... 
[bed_mesh] 
...
mesh_min: 30,10
mesh_max: 320,300
probe_count: 10,10
... 
[extruder]
...
max_extrude_cross_section: 5.0
...

 

CHC XL Thermistor Note:

The CHC XL comes with a PT1000 temperature sensor. Using it is possible but requires changing a pull-up resistor on the mainboard. If you understand what this entails, you can try it. For everyone else, the simpler method is to disassemble the CHC XL hotend, remove the PT1000, and install the original thermistor from your stock hotend (using thermal paste) into the small recess on the CHC XL. No additional configuration is needed if you use the original thermistor.

Wiring:

Heater Cartridge: I cut the connector from the original heater and crimped ferrules onto the CHC XL heater wires. The heater has no polarity, so wire order doesn't matter.

4010 Fans: I did the same for the 4010 fan connectors—cut the original connectors and crimped all three wires with ferrules, observing polarity by matching the wire colors.

Bed Leveling Sensor: The wire on my SOVOL's sensor was just long enough to connect without extension. If yours is shorter, you will need to extend the wires to the required length.

Assembly Notes:

The bed leveling sensor is mounted using its original fixing hole. You need to enlarge this hole to 3mm and heat-set a small M3 nut into it.

Cable Management is underdeveloped at the moment. All I've done is add a notch for the left 4010 fan wire. This might be improved later.

The air ducts have gone through a dozen iterations, and their effectiveness was verified in simulations. The result seems quite good. At 100% speed, the two 4010 fans are 4 dB quieter than the stock toolhead's fan, and the sound profile is more pleasant.

 

Important: If the partducts are lower than the nozzle plane, you have assembled something incorrectly. The current design has a gap of approximately ~0.5mm. Re-check your printer's calibration!

BOM (Bill of Materials):

A detailed table will be provided later. For now, you will definitely need:

• CHC XL Hotend
• 2x 4010 Fans (I used GDSTIME 12000RPM, 0.1A, 24V)
• 3x Heat-set M3 nuts (two for the hotend, one for the bed level sensor)
• 2x Heat-set M2.5 nuts
• 2x Standard M2.5 nuts (these go behind the fan for now; I will design a proper fix soon, currently they are "floating").
• M2.5x6(?) bolts for mounting the fans to the shroud.
• M2.5x35 bolt for mounting the heatsink/thermal barrier.
• M3x30 bolt for mounting the hotend.

Everything else should come from disassembling your original toolhead or is included with the CHC XL kit.

Performance:

• Achieved volumetric flow rate: PETG 40-42 mm³/s with a 0.4mm nozzle.
• My impression of the upgrade is exclusively positive, with excellent print quality.

Note on Electronics Cover:

The current electronics board cover is very tight. I am working on an improved version. It is mounted using magnets I salvaged from the bottom of the original mounting plate. It holds firmly and does not come loose.