Large all-metal Kossel Delta

  • 2040 Kossel with 330mm tooling plate mains bed, E3d v6, E3d titan "flying extruder", Hiwin rails, optical endstops.
    Full build log here,702599
    Printed Parts repository

  • This is the 3rd object it has printed. Very pleased with the controller and the build.

  • Looking good Can I ask what elastic your using for the Flying Extruder?


  • administrators

    Great looking printer and really detailed build log, thanks for putting the photos up. How much of a difference does the flying extruder make?

  • Doug, it's hairbands, the best quality ones I could steal from my Mrs.

    Tony, its hard to say on this machine as it didn't have a bowden setup before but on my kossel mini (which is one of yours) the difference was huge. Whether that's because I didn't get the bowden extruder correctly tuned in the first place is less clear, but I've been flying extruders for about 8 months and I can't really see a downside.

  • administrators

    Cool thanks for the feedback I will have to retrofit one to my big Kossel.

  • administrators


    Cool thanks for the feedback I will have to retrofit one to my big Kossel.

    Me too!

  • I am going to do the Same

  • I've moved my spool holder to the top between the towers, it really doesn't work on the side in this configuration. The only annoyance is when it homes after printing is finsihed the free filament that was pulled out when the extruder was at its lowest position now twists and kinks as it comes back up. Haven't come up with a fix for that except a spool holder that can wind the slack back on in some way, maybe a light spring with a delicate clutch.

  • I run a loose ptfe tube from the spool to the entry to the extruder, which I bundle with the wiring harness going down to the effector (I have a direct drive on my effector). Works well at keeping the filament untangled, clean, etc.

  • administrators

    Bots plan sounds good. It works for the bowden tube so would also work in this situation.. you might need another point on the frame to be the other end of the tube, like the mini kossel filament guide or similar

  • If I were to do it again (I'm using 1.75 mm filament keep in mind), I would get the size PTFE tube that they use for 3mm filament, so there was as little resistance as possible. I use a 2mm one now, and when the filament is really kinky (wrinkled not 😉 ) or I've approached the end of the roll and it's really tight, it adds unnecessary friction into the process. I also don't have it attached at the top; the top end of the tube can sometimes come in direct contact with the spool. almost wrapping itself around it. I find this helps keeping the spool spooled, and tidy, without the filament flying off like crazy.

    I would, however, prefer to secure the lower portion precisely above where it is fed into the extruder, possibly even reducing the tube to the 2 mm variety for the last 5-10 mm or so, to guide it. Right now, it kinda just "finds" its way in there, and I think the precision of the extrusion can be slightly improved by fixing the entry point better.

  • I've always found that whenever I've made spool holders with bearings the filament comes off them much less well, more prone to slip a loop off the reel and spin back and forth, a little bit of friction with the spool holder helps.

  • @Dougal1957:

    Looking good Can I ask what elastic your using for the Flying Extruder?


    I recommend using this stuff:

    been using it on mine for years, seems fine! its a type of TPU…

    good looking build by the way!!!!

    I think you would also enjoy my build...

    its about the same size 🙂


  • Looks good Russ. Wonderfully detailed build - and you really did build it and make almost everything. I just bought a bunch of stuff and bolted it together. When I get chance I will watch through your videos.

  • Thanks, something about making all the parts, yeah it takes a lot of time but now i can say " i made that" lol there is always something tho like the electronics that are just much better to buy…

    also i have a question. my kids got a hold of my printer and ran the arms up and down, breaking some of course. but what ever lol it happens...

    my question is do your motors at a stand still at 100% power squeal ?

    I ran the Wifi Duet previously but only got about 2 use's out of it and i cant remember if the motor had that bad squeal.

    the reason i ask is i know the kids ran those rail's up and down and drove a lot of power in to the drivers... go figure. so i was wanting some one else to confirm that there motors don't make a squeal sound when parked at full power... they still run fine and quiet too but now i'm worried that the drivers may be damaged...



  • My motors make a high pitched noise when powered up and holding at 100% but its not particularly distressing either that or my ears are old enough that its barely audible to me. My understanding of the stepper drivers is that they have a lot of built in protection so they will shut down to protect themselves and the motors if they are repeatedly asked to perform movements at speeds that are dangerous.

  • Well I never thought I'd see this:

    16:15:37Stopped at height -0.150 mm
    Calibrated 8 factors using 10 points, deviation before 2.630 after 0.001
    16:07:55G10 P0 S130
    16:07:52M140 S85
    16:07:49Connection established!
    16:07:45Page Load complete!

    That's only probing the central 100mm of my kossel XL bed, with my piezo probe using an experimental build surface on glass, but deviation 0.001 - happy with that would be one way of putting it.

  • administrators

    (thumbs up emoji)!

  • @DjDemonD Can you try 20-30 random points instead of 10?

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