Icarus 2 Remix

Note

The process of reverse engineering the Icarus gave me a great appreciation for the effort Hume must have gone through to design it. There are so many dependencies and constraints. I have done my best to make this remix compatible with original, but I have no plans to upgrade, improve this remix so I would only use it if you want to take advantage of Hume's design with a BMG or similar extruder, or find yourself swapping extruder chassis on a regular basis.

Remix Goals

1. Provide clearance for the BMG extruder.
2. Make it easy to remove and install the carriage. Removing the carriage is challenging because
   • Four screws secure the layer fan duct,
   • The screws holding the belt tensioner pass through the carriage frame so the belt tensioner has to be disassembled, and
   • The ribbon cable support has a retention screw.
3. Improve airflow from the turbine fan to the layer fan duct.
4. Retain compatibility where possible.

Changes

1. Made the layer fan duct a snap-fit by adding retention tabs on the top of the duct and indentations into the carriage and reduced the height of the duct 2mm to provide more clearance/visibility.
2. Moved the belt mount/tensioner to the outside of the carriage. With this modification the clip assembly can be removed from the chassis with just two screws without messing with the belts tension.
3. Increased layer fan air flow by changing the turbine fan connection from the inside to the outside of the fan housing and increased the dimensions of the frame to duct connection.
4. Moved the turbine fan to the right (away from the ribbon cable support) to allow for angling the ribbon support.
5. Replaced the ribbon cable support retention screw with a cap. Also added an offset at the top of the slot so that the cap is optional.
6. The ribbon cable guide fits into a pocket so that it is removable to make access to the ribbon cable connector easier. A retention screw and nut are optional.
7. Included the option for an angled ribbon cable guide where clearance is needed.
8. Did not include the dial gauge mount. I use this instead: https://www.printables.com/model/59210-qidi-x-max-dial-indicator-carriage-and-bed-levelin

Printing

• Use the stiffest filament you can. I am using Priline’s Super Hard carbon fiber PC. I found that the structure has to be really stiff, rigid, hard, strong, no deflection, etc. I recently reprinted using a PETG/PC blend and had really bad bed first layer adhesion issues. Turned out that blend flexed just enough that the nozzle was forced up by the pressure at the tip of the nozzle.
• I do not recommend any Nylons, with or without CF, they are too flexible and prone to deformation when warmed with pressure applied. Enhanced PLA might work if you are not planning to print in hot chamber.