X-Max (X-Plus) Linear Rail Upgrade: Carriage for Universal Geared Dual Drive Extruder/E3D V6 Hot End

UPDATE 15 Jan 2023: More robust frame and other improvements.

This carriage and extruder setup weighs 40% less and slides much more smoothly with increased movement accuracy on the linear rail than the stock Qidi extruder/carriage.

The associated linear rail gantry files can be found here: https://www.printables.com/model/272447-x-max-x-pro-gantry-linear-rail-upgrade

STEP files are provided to facilitate remixes and alternative extruder mounting options.

Note: The carriage frame has only been tested with a BMG extruder and Dragon Hot End.

Features:

• The Layer Fan Duct snaps into place instead of using screws or magnets
• The Layer Fan Mount slides into place instead of using screws
• The Layer Fan Mount/Duct can be substituted with a standoff
• The Belt Clip can be detached from frame without disconnecting or adjusting the belt
• Extruder and hot end can be removed from the carriage without detaching the carriage

Printing:

• All the files are designed to be printed as orientated without supports except for the ‘PCB and Fan Mount’.
• 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.
• I used 4 walls, 4 top and 4 bottom layers and 40% cubic infill with 40% overlap. All other setting adjustments were based on flow cubes and temp towers.

Post Printing:

• The frame requires two inserts for the Belt Base, one insert for the PCB and Fan Mount and two M3 nuts for the Ribbon Guide.
• The PCB and Fan Mount requires four inserts.
• The Belt Base requires one M3 nut.
• The radial fan mount requires two inserts.

Assembly:

• The PCB and Fan Mount fits onto the front of the Frame and is held in place with a screw.
• The Ribbon Guide is fitted to the side of the Frame. Note that there is space behind the guide to hold the motor wires in place.
• The Radial Fan mount simply slides into place.
• The Layer Duct snapping mechanism can be adjusted by filing material away or using super glue to add material back. Make sure to clean up any elephants foot on the parts. When snapping the duct onto the fan board, use a tool such as a screw driver to provide support to the fan board. The duct pivots on the base of the mount into/out of position.
• The Belt Clip Base is fitted to the back of the Frame.

BoM:

Description	Amazon U.S.	Image
M3x5.7mm, OD4.6mm Threaded Brass Insert	https://a.co/d/6rNIbp1
Stainless Steel M3 Hex Socket Head Cap Screws and Nuts Assortment	https://a.co/d/1ef5smv
DDB Universal Geared Dual Drive Extruder	https://a.co/d/bIT0TX7