Orbiter 2 Filament (Extruder) Sensor For ERCF

This is a modified Orbiter 2 filament sensor body that is designed to be used with the ERCF system as an extruder sensor.  It could also be used as an ordinary filament sensor, but the sensor the Orbiter creator built is great so I'd recommend going that route if you're not doing multi-material.  

This design utilizes and ECAS fitting to keep the filament tube secure during color swaps, and it uses a simple D2F-L type microswitch with a 6mm steel ball to sense the filament.  The microswitch is held in place with 2 x M2x10mm sockethead cap screws that are self-tapping.  That's all you need!  

The sensor body in the pictures is printed in PC with 0.20mm layer height, 0.4mm layer width, 2 walls, 75% infill, rectilinear infill.  If you're using ABS or ASA, the Oriber website suggests my settings except for 0.15mm-0.20mm layers, 3 walls, 100% infill.  They also suggest using supports on the build-plate, which I forgot to use for my print.  It turned out fine with some clean-up, however.  

I do recommend that before fitting the ECAS, that you first clean the filament hole out with a 2.5mm drillbit, it shouldn't take much.   You can cleanup the ECAS hole with an 8mm drillbit to get rid of any strings from the printing overhang.  The smoother these holes are the better chance you will have with successful filament changes!  

I used a 6mm ball, which is what the stock Orbiter sensor uses, but I've included the STEP file so you can re-mix for the ball size that suits your needs.  

Happy Printing!