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v0.8

Minor Versionm

Approved Bondtech QC Lite

by Nuno Santiago

Introduction

Bondtech's Product Page

This Guide relates to the following Bondtech Direct Drive upgrade kit and Adapter Set:

DDX Direct Drive eXtruder for Creality

DDX Adapter Set For Creality Ender-3 / CR-10

Know more about the DDX here:

About the DDX Direct Drive eXtruder for Creality

Compatibility

This guide can also be used to install a DDX on a Ender-5, CR-10 and CR-10S.


Previous Requirements

The actions in this guide should be performed only after the ones from the following guide:

01. Stripping Down Your Creality Ender-3


You will need :

The Capricorn Cutting Fixture you must print before stripping down your 3D printer.

And the following:

    • Before continuing, make sure the 3D printer is switched OFF.

    • Connecting or disconnecting stepper motor cables with the printer ON, may damage the stepper motor drivers.

  1. Before connecting the extension cable we ship with the DDX perform the following 2 checks: Check the cable extension wires match the switch shown on the first image.
    • Before connecting the extension cable we ship with the DDX perform the following 2 checks:

    • Check the cable extension wires match the switch shown on the first image.

    • Check the stock extruder cable has the middle pair of wires switched like you can check on the second image.

    • If the wires are not properly switched, there is the risk of damaging the stepper motor drivers.

  2. The Ender-3 DDX Adapter Set includes: Hotend Adaptor (for Ender-3, Ender-5, CR-10, and CR-10S hotends) Align the Adapter so its front flat face aligns with the outer face of the heater block.
    • The Ender-3 DDX Adapter Set includes:

    • Hotend Adaptor (for Ender-3, Ender-5, CR-10, and CR-10S hotends)

    • Align the Adapter so its front flat face aligns with the outer face of the heater block.

    • Take the Hotend Adapter and place it on the hotend.

    • Align the holes from the adapter with the mounting holes from the hotend.

    • Push it all the way down so the holes align.

  3. Use 2 M3x20mm screws supplied with the kit (the washers are optional here). Pair screws and washers. Insert each pair in a mounting hole.
    • Use 2 M3x20mm screws supplied with the kit (the washers are optional here).

    • Pair screws and washers.

    • Insert each pair in a mounting hole.

  4. This is a very important step to improve the work quality of the existing hotend. Take the Capricorn tube that comes with the kit. You will use the 3D printed fixture to guide your cut.
    • This is a very important step to improve the work quality of the existing hotend.

    • Take the Capricorn tube that comes with the kit.

    • You will use the 3D printed fixture to guide your cut.

    • Insert the Capricorn into the hotend, and push it all the way down. Press it straight.

    • Make sure the Capricorn is all the way down to the nozzle. Push hard.

    • Push the fixture through the Capricorn tube.

  5. Push the fixture all the way until it is blocked by the hotend adapter. Tuck the Capricorn in again to make sure it is all the way down the hotend. Press the fixture against the adapter.
    • Push the fixture all the way until it is blocked by the hotend adapter.

    • Tuck the Capricorn in again to make sure it is all the way down the hotend.

    • Press the fixture against the adapter.

    • The motion in next step should be made as vertical as possible, to end-up with a clean and straight cut.

    • Use the Hobby Knife

    • Cut the Capricorn guided by the fixture slot.

    • There should be 5 mm of outstanding Capricorn tube.

  6. Use the 2.5 Hex Key Unscrew the 2 screws on the back of the DDX. No need to remove them completely from the holes.
    • Use the 2.5 Hex Key

    • Unscrew the 2 screws on the back of the DDX.

    • No need to remove them completely from the holes.

    • Move both halves apart about 2mm in a perpendicular to split line way.

    • The hotend can be placed inside without splitting completely the DDX housing.

  7. Take the screws out of the hotend assembly. Insert the Hotend assembly in between the two DDX housing halves. Tilt the back housing a bit so it is easier to fit the hotend in.
    • Take the screws out of the hotend assembly.

    • Insert the Hotend assembly in between the two DDX housing halves.

    • Tilt the back housing a bit so it is easier to fit the hotend in.

  8. Before the next step, make sure the 2 cables of the front fan (red and black pair on this image) pass between the DDX and the Thermistor and Heater cables. Not like we did here : ) Push the hotend all the way in and up the DDX. Align the mounting holes of the DDX with the mounting holes of the hotend.
    • Before the next step, make sure the 2 cables of the front fan (red and black pair on this image) pass between the DDX and the Thermistor and Heater cables. Not like we did here : )

    • Push the hotend all the way in and up the DDX.

    • Align the mounting holes of the DDX with the mounting holes of the hotend.

    • Insert the two M3x20mm screws and washers in the holes.

  9. While pressing the hotend all the way up the DDX... ...and keeping the holes aligned...
    • While pressing the hotend all the way up the DDX...

    • ...and keeping the holes aligned...

    • Use the 2.5 Hex Key

    • ...tighten both screws on the back to close the DDX.

  10. Insert a zip-tie supplied with the upgrade kit into the inner hole on the back of the DDX. The zip-tie will exit on the outer side. Conform the main cable to the groove and guide it through the zip-tie.
    • Insert a zip-tie supplied with the upgrade kit into the inner hole on the back of the DDX.

    • The zip-tie will exit on the outer side.

    • Conform the main cable to the groove and guide it through the zip-tie.

    • Please notice that:

    • The hole to the right is used on the CR-10S-Pro and compatible models.

  11. While holding the main cable in the groove and between the zip-tie ends Move the DDX towards the x-carriage and align the holes with the mounting points. Push it against the x-carriage plate.
    • While holding the main cable in the groove and between the zip-tie ends

    • Move the DDX towards the x-carriage and align the holes with the mounting points.

    • Push it against the x-carriage plate.

  12. Keep the DDX vertically aligned Tighten the mounting screws Make sure the fan cables are loose on the side of the DDX.
    • Keep the DDX vertically aligned

    • Tighten the mounting screws

    • Make sure the fan cables are loose on the side of the DDX.

    • The images on this step should show the front fan wires (black and red pair) between the DDX and the Heater and Thermistor cables.

    • This error was corrected off-camera. A detailed explanation on how these cables should be is in the next step.

  13. This step is only to show how the front fan should be managed. The black and red pair (on this picture. other printers may have other colors) should come to the front between the DDX and the Thermistor and Heater cables.
    • This step is only to show how the front fan should be managed.

    • The black and red pair (on this picture. other printers may have other colors) should come to the front between the DDX and the Thermistor and Heater cables.

    • That way it will be able to use the cable management grooves without obstacle.

  14. Before proceding: Make sure the DDX is vertically aligned
    • Before proceding:

    • Make sure the DDX is vertically aligned

    • and the back of the DDX is flat against the x-carriage plate.

  15. The DDX for Creality includes: Stepper Motor Cable Extension. Plug it to the stepper motor connector
    • The DDX for Creality includes:

    • Stepper Motor Cable Extension.

    • Plug it to the stepper motor connector

    • Guide the cable through the cable management grooves.

  16. Guide the stepper motor extension cable through the zip-tie Half tighten the zip-tie to hold the cables Stretch the stepper motor extension cable to conform it to the grooves.
    • Guide the stepper motor extension cable through the zip-tie

    • Half tighten the zip-tie to hold the cables

    • Stretch the stepper motor extension cable to conform it to the grooves.

    • Keep the zip-tie loose. It will require adjustment later.

  17. Apply 2 more zip-ties from the upgrade kit. Put regular space intervals between them. No need to fully tie them now. They will be adjusted later.
    • Apply 2 more zip-ties from the upgrade kit.

    • Put regular space intervals between them.

    • No need to fully tie them now. They will be adjusted later.

  18. We supply 60cm of PTFE tube with the upgrade kit. Depending how you want to manage the filament feeding, you will need to cut the PTFE longer or shorter.
    • We supply 60cm of PTFE tube with the upgrade kit.

    • Depending how you want to manage the filament feeding, you will need to cut the PTFE longer or shorter.

    • Define your filament feeding strategy and check how long you need the PTFE to be before doing the cut.

    • On our unit we place the spool holder on the top of the frame and feed the filament straight down.

    • We used only about 6cm.

    • Insert one end of the PTFE tube into the push-fit.

  19. The DDX for Creality includes Two cable and tube clips Apply one clip to the cables
    • The DDX for Creality includes

    • Two cable and tube clips

    • Apply one clip to the cables

    • And attach them to the PTFE tube.

    • You can choose the other place where you can apply the second clip, or not at all.

  20. The DDX Adapter Set for Ender-3  includes: SLS printed fan shroud. This screw was stripped from the printer, where it was fastening the side (radial) fan.
    • The DDX Adapter Set for Ender-3 includes:

    • SLS printed fan shroud.

    • This screw was stripped from the printer, where it was fastening the side (radial) fan.

    • Fit the fan shroud on the bottom of the side fan.

    • Use the screw to lock it in place, and tighten from the back.

  21. The DDX Adapter Set for Ender-3  includes: SLS Fan Holder Place the SLS Fan Holder with the arrow pointing upwards and facing against the back of the side fan.
    • The DDX Adapter Set for Ender-3 includes:

    • SLS Fan Holder

    • Place the SLS Fan Holder with the arrow pointing upwards and facing against the back of the side fan.

    • Use the longest screw stripped from the printer that was fastening the fan.

  22. Use another of the screws stripped from the printer. Check if the SLS Fan Holder is well tight. and pointing down as shown in the picture.
    • Use another of the screws stripped from the printer.

    • Check if the SLS Fan Holder is well tight.

    • and pointing down as shown in the picture.

  23. The DDX upgrade kit includes: 1x M3x10 screw button head. Cross the screw through the radial fan slot from the inside outwards.
    • The DDX upgrade kit includes:

    • 1x M3x10 screw button head.

    • Cross the screw through the radial fan slot from the inside outwards.

    • Align it with the hole of the SLS Fan Holder

    • screw it in the metal threaded insert

    • do not tighten it fully. We will need to adjust the fan height during next step.

    • When tightening a screw onto a metal threaded insert use at most 0.4Nm torque.

    • Using excessive torque will damage the laser sintered nylon that holds the metal insert in place.

  24. If the screw holding the SLS Fan Holder is not too tight, you will notice the radial fan and fan shroud can move up and down. Push the fan down and use the available clearence to manage the cables behind. Then bring it back up again.
    • If the screw holding the SLS Fan Holder is not too tight, you will notice the radial fan and fan shroud can move up and down.

    • Push the fan down and use the available clearence to manage the cables behind.

    • Then bring it back up again.

    • Hold it in there.

  25. The side fan can move up and down, to adjust to different hotends if necessary. Level it to be about 2mm above the nozzle tip. And when in position, tighten the holding screw.
    • The side fan can move up and down, to adjust to different hotends if necessary.

    • Level it to be about 2mm above the nozzle tip.

    • And when in position, tighten the holding screw.

  26. The DDX upgrade kit includes: 3x M3x12 screws Place them inside the 3 slots indicated in the picture.
    • The DDX upgrade kit includes:

    • 3x M3x12 screws

    • Place them inside the 3 slots indicated in the picture.

    • Move the fan to align the top left hand side screw with the respective metal threaded insert.

    • Finish installing the axial fan by tightening the screws.

    • When tightening a screw onto a metal threaded insert use at most 0.4Nm torque.

    • Using excessive torque will damage the laser sintered nylon that holds the metal insert in place.

  27. Doing the procedure below, don't use too much force to pull or you may damage the cables. Do it carefully. These cable are fragile. Pull the radial and axial fan cables to get them adjusted to the DDX housing. Use a hex-key to help put them in place.
    • Doing the procedure below, don't use too much force to pull or you may damage the cables. Do it carefully. These cable are fragile.

    • Pull the radial and axial fan cables to get them adjusted to the DDX housing.

    • Use a hex-key to help put them in place.

  28. Doing the procedure below, don't use too much force to pull or you may damage the cables. Do it carefully. These cable are fragile. Pull the radial and axial fan cables to get them adjusted to the DDX housing. Use a hex-key to help put them in place.
    • Doing the procedure below, don't use too much force to pull or you may damage the cables. Do it carefully. These cable are fragile.

    • Pull the radial and axial fan cables to get them adjusted to the DDX housing.

    • Use a hex-key to help put them in place.

  29. Pull the cable sleeve upwards until it covers the cables beneath the DDX zip-tie. Tighten the Zip-tie
    • Pull the cable sleeve upwards

    • until it covers the cables beneath the DDX zip-tie.

    • Tighten the Zip-tie

  30. Put the clip back into place. Place some zip-ties along the main cable We recommend to distribute 3 zip-ties.
    • Put the clip back into place.

    • Place some zip-ties along the main cable

    • We recommend to distribute 3 zip-ties.

  31. Push the carriage all the way till the end of the x-axis. And grab the cable with the original clip in the extruder plate, with enough cable slack to allow the extruder to move all the way freely. Use one zip-tie near each side of the clip to get the cables stable.
    • Push the carriage all the way till the end of the x-axis.

    • And grab the cable with the original clip in the extruder plate, with enough cable slack to allow the extruder to move all the way freely.

    • Use one zip-tie near each side of the clip to get the cables stable.

  32. Clip all the cable zip-ties. Clip the DDX zip-tie. and tuck the zip-tie lock in the back groove of the DDX.
    • Clip all the cable zip-ties.

    • Clip the DDX zip-tie.

    • and tuck the zip-tie lock in the back groove of the DDX.

  33. To finish the installation, connect the extension cable connector to the original stepper motor connector. To finish the installation, connect the extension cable connector to the original stepper motor connector.
    • To finish the installation, connect the extension cable connector to the original stepper motor connector.

    • Due to the fact that the DDX uses a 3:1 gearing ratio and includes a stepper motor that is rated to run at 0.7A, nearly half of the current stock Creality stepper motors run at, we recommend to lower the Vref of the driver serving the extruder motor.

    • The following guide will help you with the task:

    • 06. Stepper Current Adjustment On CR-10S

  34. 3 STEPS UNTIL YOU ARE READY 2 PRINT
Conclusion

The installation is almost done.

3 things are missing before you are ready to print:

  1. Remember to properly tighten the thumb screw. Find out how to do it here: tighten thumbscrew
  2. Perform a bed levelling.
  3. Change The Machine Settings using Cura.

Nuno Santiago

Member since: 04/02/2019

37 Guides authored

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