CREALITY ENDER 5 PLUS - COREXY CONVERSION (8MM RODS & 10MM BELTS)

This project is a complete engineering overhaul for the Creality Ender 5 Plus, transforming its kinematics from the stock Cartesian system into a high-performance CoreXY motion system.

By utilizing heavy-duty 10mm GT2 belts, 8mm linear rods, and LM8UU bearings, this modification significantly increases print speeds and accelerations while maintaining the massive build volume of the Ender 5 Plus. The main design philosophy was to minimize structural changes to the original frame while maximizing rigidity.

--- PROJECT STATUS & SHARED FILES ---

• Work in Progress: The Bill of Materials (BOM) regarding the exact count of screws, nuts, and heat-set inserts is currently incomplete.

• Files Included:

  1. A folder containing only the printable plastic parts.

  2. A comprehensive assembly model provided in .step format, featuring the frame, pulleys, toolhead, and partial insert placements for easy reference during assembly.

--- REMIX INFORMATION & TOOLHEAD NOTES --- This project includes a remixed "BambuLabs SB Adapter" based on the following publication: https://www.printables.com/model/323196-voron-stealthburner-for-bambu-lab-x1cx1-hotend

• Modification: The positions of the mounting screw holes have been changed.

• Important Compatibility Note: The Stealthburner housing from the linked model (as well as the original Voron model) is NOT compatible with the bed probe mount (BLTouch) used in this project.

--- KEY FEATURES & SPECIFICATIONS ---

• Kinematics: CoreXY conversion with minimal frame modification.

• Frame Requirements: Requires removing stock Cartesian motion brackets and installing the provided frame-stiffening mounts. No drilling or permanent frame destruction needed.

• Motion System:

  • Y-Axis: 4x 510mm linear rods (dual rods per side).

  • X-Axis: 2x 440mm linear rods.

  • Bearings: 8x LM8UU linear bearings in total (2 for the X-carriage, and 3 per side for the X/Y gantry mounts - arranged with two back-to-back on the lower rod and one on the upper rod).

• Drive Mechanics: High-torque 10mm wide GT2 belts.

• Toolhead: Custom Stealthburner toolhead housing a Bambu Lab X1C Hotend, Orbiter 2.0 Extruder, and a BLTouch probe.

• Electronics Relocation: Requires relocating the mainboard and power supply from the stock bottom box to the side of the frame. This mod is fully compatible with this external enclosure project: https://www.thingiverse.com/thing:4790166

--- TECHNICAL COMPONENT LIST (HARDWARE BOM) ---

Motion & Frame:

• Motors: 2x LDO Nema 17 (42STH48-2504AC) mounted in the rear corners.

• Belts: GT2 10mm open-ended belt.

• Linear Rods (8mm diameter): Y-Axis 4x 510 mm, X-Axis 2x 454 mm.

• Bearings: 8x LM8UU linear bearings.

• Pulleys & Idlers (10mm width, 5mm bore):

  • Front Corners: 1x smooth idler on each side (2 total).

  • Rear Corners: 3x smooth idlers on each side integrated with the belt tensioning system (6 total).

  • X-Axis Gantry Mounts: 2x idlers on each side (4 total). Note: Since the belt flips in this section, you can use smooth idlers or substitute one on each side for a toothed pulley.

Toolhead, Sensors & Electronics:

• Hotend: Bambu Lab X1C

• Extruder: Orbiter 2.0

• Z-Probe: BLTouch (mounts alongside the ADXL345 accelerometer on a dedicated bracket).

• Part Cooling Fan: SUNLU 24V Blower Fan.

• Mainboard: BigTreeTech SKR Mini E3.

--- RECOMMENDED PRINT PARAMETERS --- Since this modification bears structural load and handles high accelerations, parts must be printed with high-strength, temperature-resistant materials.

• Material: ABS, ASA, or PC (Polycarbonate) but remeber to bake PC-printed parts

• Perimeters (Walls): 6-12

• Top/Bottom Layers: 5

• Infill: 20% 

• Layer Height: 0.16mm - 0.20mm

--- KLIPPER FIRMWARE CONFIGURATION (printer.cfg) --- Incorporate the following block into your Klipper configuration. It is pre-tuned for Sensorless Homing on X and Y axes using TMC2209 drivers and optimized for high-speed capabilities (max_velocity: 700, max_accel: 15000).

# See the example.cfg file for a description of available parameters.
[stepper_x]
step_pin: PD4
dir_pin: PD3
enable_pin: !PD6
microsteps: 128
rotation_distance: 40
endstop_pin: tmc2209_stepper_x:virtual_endstop #^PC1
homing_retract_dist: 0
position_endstop: 350
position_max: 350
homing_speed: 100
;homing_positive_dir: false
[stepper_y]
step_pin: PA15
dir_pin: PA8
enable_pin: !PD1
microsteps: 128
rotation_distance: 40
endstop_pin: tmc2209_stepper_y:virtual_endstop#^PC3
homing_retract_dist: 0
position_endstop: 355
position_max: 355
position_min: -12
homing_speed: 100
[stepper_z]
step_pin: PE2
dir_pin: !PE3
enable_pin: !PE0
microsteps: 32
rotation_distance: 1.9825 #2.0 #3.965
endstop_pin: probe:z_virtual_endstop
position_max: 400
position_min: -5 #set position_min to a negative value such as -5 when probing to set z offset, then revert to 0
homing_speed: 10.0
########################################
TMC2209 configuration
########################################
[tmc2209 stepper_x]
uart_pin: PD5
run_current: 1.6
hold_current: 0.55
interpolate: false
sense_resistor: 0.110
stealthchop_threshold: 0
diag_pin: ^PC1      # Set to MCU pin connected to TMC DIAG pin
driver_SGTHRS: 115  # 255 is most sensitive value, 0 is least sensitive
driver_TBL: 1
driver_TOFF: 3
[tmc2209 stepper_y]
uart_pin: PD0
run_current: 1.6
hold_current: 0.55
interpolate: false
sense_resistor: 0.110
stealthchop_threshold: 0
diag_pin: ^PC3      # Set to MCU pin connected to TMC DIAG pin
driver_SGTHRS: 115  # 255 is most sensitive value, 0 is least sensitive
driver_TBL: 1
driver_TOFF: 3
[tmc2209 stepper_z]
uart_pin: PE1
run_current: 0.7
hold_current: 0.4
interpolate: False #true
sense_resistor: 0.110
stealthchop_threshold: 0 #999999
[tmc2209 extruder]
uart_pin: PC6
run_current: 0.85
hold_current: 0.1
interpolate: true
sense_resistor: 0.110
stealthchop_threshold: 0
driver_TBL: 0
driver_HEND: 6
driver_HSTRT: 7
driver_TOFF: 4
[extruder]
step_pin: PD15
dir_pin: PD14
enable_pin: !PC7
microsteps: 16
full_steps_per_rotation: 200
rotation_distance: 4.711
nozzle_diameter: 0.400
filament_diameter: 1.750
max_extrude_only_velocity: 120
max_extrude_only_distance: 150
max_extrude_only_accel: 6500
heater_pin: PB3
sensor_type: Generic 3950
sensor_pin: PA2
smooth_time: 2.0
control = pid
pid_kp = 27.902
pid_ki = 1.368
pid_kd = 142.298
min_temp: 0
max_temp: 290
min_extrude_temp: 160
[heater_bed]
heater_pin: PD7
sensor_type: EPCOS 100K B57560G104F
sensor_pin: PA1
control = pid
pid_kp = 67.822
pid_ki = 0.810
pid_kd = 1419.177
min_temp: 0
max_temp: 120 #max value 100
[fan]
pin: PB7
max_power: 1.0
cycle_time: 0.001
hardware_pwm: false
kick_start_time: 0.2
off_below: 0.16
[heater_fan heat_sink_fan]
pin: PB6
max_power: 1.0
fan_speed: 1.0
heater: extruder
heater_temp: 50.0
[safe_z_home]
home_xy_position: 175, 175
speed: 100
z_hop: 10 # Move up 10mm, so the probe doesnt hit anything
z_hop_speed: 5
########################################
PRINTER ADXL345
########################################
[mcu rpi]
serial: /tmp/klipper_host_mcu
[adxl345]
cs_pin: rpi:None
[resonance_tester]
accel_chip: adxl345
probe_points:
    175, 175, 20  # an example
########################################
PRINTER COMUNICATION
########################################
[mcu]
serial: /dev/serial/by-id/usb-Klipper_stm32h723xx_(to_configure!!!!)
[virtual_sdcard]
path: /home/pi/printer_data/gcodes
on_error_gcode: CANCEL_PRINT
[pause_resume]
recover_velocity: 50 #allows pause resume functionality.
[exclude_object]
[gcode_arcs]
resolution: 0.1
[display_status]
########################################
PRINTER CONFIG
########################################
[printer]
kinematics: corexy
max_velocity: 700
max_accel: 15000 # 20x print speed recommended
max_z_velocity: 5
max_z_accel: 100
square_corner_velocity: 5.0
[input_shaper]
shaper_freq_x: 41.74
shaper_type_x: mzv
shaper_freq_y: 37.04
shaper_type_y: mzv
[bltouch]
sensor_pin: ^PC0
control_pin: PE5
probe_with_touch_mode: True
stow_on_each_sample: false
x_offset: -29
y_offset: 8
z_offset: 0
speed: 3.0
samples: 1
samples_result: average
sample_retract_dist: 2
samples_tolerance: 0.02
samples_tolerance_retries: 15
pin_up_reports_not_triggered: True
pin_up_touch_mode_reports_triggered: True
[bed_mesh]
speed: 180
horizontal_move_z: 5
mesh_min: 10, 10
mesh_max: 321, 350
probe_count: 10, 10
mesh_pps: 2, 3
algorithm: bicubic
fade_start: 1
fade_end: 10
fade_target: 0
[bed_screws]
screw1: 175, 175
screw2: 10, 310
screw3: 310, 310
screw4: 310, 30
screw5: 30, 30
[temperature_sensor raspberry_pi] #pi
sensor_type: temperature_host
min_temp: 10
max_temp: 100
[temperature_sensor mcu_temp] #pi
sensor_type: temperature_mcu
min_temp: 0
max_temp: 100
[force_move]
enable_force_move: true
#filament runout sensor
[filament_switch_sensor filament_sensor]
switch_pin:PC2
pause_on_runout: True #pause handled by macro
runout_gcode:
    M600 #calls a macro with the name M600 (so it can be called by slicers too)
event_delay: 3.0
pause_delay: 0.0001
[save_variables]
filename: ~/savedVariables1.cfg
#[include macros.cfg]
[idle_timeout]
gcode:
A list of G-Code commands to execute on an idle timeout. See
docs/Command_Templates.md for G-Code format. The default is to run
"TURN_OFF_HEATERS" and "M84".
timeout: 600
Idle time (in seconds) to wait before running the above G-Code
commands. The default is 600 seconds.

--- FUTURE DEVELOPMENT & ROADMAP --- Future updates will incorporate:

• A custom multi-material filament runout sensor/inlet is currently being refined (designed to route 4 filaments via PTFE tubes merging into a single path 6cm before the extruder) and will be released once finalized.

Happy printing!