Feeding Both Filament And Electrons Through A Custom D-Sub Connector

How to Feed Both Filament and Electrons Through a Custom D-Sub Connector

If you are looking for a way to connect your 3D printer's extruder to a power supply and a filament spool, you might be interested in this project by Brian Benchoff. He shows how to feed both filament and electrons through a custom D-Sub connector, using some clever modifications and a few off-the-shelf parts.

A D-Sub connector is a type of electrical connector that has a D-shaped metal shield and a number of pins or sockets. They are commonly used for serial and parallel ports, video signals, and other applications. Brian wanted to use a D-Sub connector to connect his extruder to a power supply and a filament spool, but he faced two challenges: how to fit both the filament and the wires through the connector, and how to prevent the filament from twisting and tangling.

To solve the first challenge, he decided to use a 25-pin D-Sub connector and modify it by drilling a hole through the center of the metal shield. He then inserted a piece of PTFE tubing through the hole, which would act as a guide for the filament. He also soldered wires to some of the pins on the connector, which would carry the power and control signals for the extruder.

To solve the second challenge, he designed and 3D printed a custom spool holder that would attach to the back of the D-Sub connector. The spool holder has a bearing that allows the spool to rotate freely, and a spring-loaded arm that applies tension to the filament. This way, the filament can be fed smoothly through the PTFE tubing without twisting or tangling.

With this setup, Brian can easily connect and disconnect his extruder from his 3D printer, without having to deal with multiple wires and tubes. He can also swap out different filaments quickly and conveniently. He says that this project was inspired by a modular extruder design by Tom Nardi, which also used a D-Sub connector for easy swapping.

If you want to learn more about this project, you can check out Brian's original article on Hackaday, where he explains the details of his modifications and provides links to the 3D models and parts list. You can also watch his video demonstration on YouTube, where he shows how his custom D-Sub connector works in action.

Why Use a Custom D-Sub Connector

There are several benefits of using a custom D-Sub connector for your 3D printer's extruder. First of all, it simplifies the wiring and reduces the clutter on your printer. Instead of having multiple wires and tubes running from your extruder to your power supply and filament spool, you only have one connector that carries everything. This makes it easier to manage and troubleshoot your printer.

Secondly, it allows you to swap out different extruders and filaments quickly and conveniently. You can have multiple D-Sub connectors with different extruders and filaments attached to them, and switch them as needed. This way, you can experiment with different materials and settings without wasting time and filament. You can also use different extruders for different purposes, such as a dual extruder for multi-color printing, or a direct drive extruder for flexible filaments.

Thirdly, it adds some modularity and customization to your 3D printer. You can design and print your own D-Sub connectors and spool holders to suit your preferences and needs. You can also modify existing connectors and spool holders to fit different types of filaments and extruders. You can even add some features and functions to your connectors and spool holders, such as sensors, LEDs, or buttons.

How to Make Your Own Custom D-Sub Connector

If you want to make your own custom D-Sub connector for your 3D printer's extruder, you will need some basic tools and materials. Here is a list of what you will need:

A 25-pin D-Sub connector (male or female depending on your extruder)

A piece of PTFE tubing (about 10 cm long and 2 mm in diameter)

A drill bit (about 3 mm in diameter)

A soldering iron and some solder

Some wires (about 20 cm long each)

A 3D printed spool holder (you can use Brian's model or design your own)

A filament spool (any size and material that fits your spool holder)

A bearing (that fits your spool holder)

A spring (that fits your spool holder)

Some screws and nuts (to attach the spool holder to the D-Sub connector)

Here are the steps to make your own custom D-Sub connector:

Drill a hole through the center of the metal shield of the D-Sub connector. Make sure the hole is big enough for the PTFE tubing to fit through.

Insert the PTFE tubing through the hole, leaving some slack on both ends.

Solder wires to some of the pins on the D-Sub connector. You will need at least four wires: two for power (+ and -) and two for control (signal and ground). You can use more wires if you want to add more functions to your extruder, such as a fan or a thermistor.

Attach the spool holder to the back of the D-Sub connector using screws and nuts. Make sure the bearing is aligned with the PTFE tubing.

Load the filament spool onto the spool holder. Make sure the filament goes through the PTFE tubing smoothly.

Connect the other end of the PTFE tubing to your extruder. Make sure there are no kinks or bends in the tubing.

Connect the other end of the wires to your power supply and controller board. Make sure you match the polarity and signals correctly.

You have now made your own custom D-Sub connector for your 3D printer's extruder. You can test it by turning on your printer and sending some commands to your extruder. You should see the filament moving through the PTFE tubing and coming out of the nozzle. aa16f39245