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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 Pro and Ender-5 Plus.


Previous Requirements

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

01. Stripping Down Your Creality Ender-5


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:
    • The Ender-3 DDX Adapter Set includes:

    • SLS Hotend Adapter

    • SLS Fan Holder

    • SLS Fan Shroud

    • Do not continue if you haven't 3D printed the:

    • Fixture to cut the Capricorn tube

    • You will also need the washers and the M2 screws holding the part cooling fan from the Ender-5 strip.

    • Remaining elements come with the DDX: mounting screws, Capricorn tube.

  3. Fit the Hotend Adapter to the top of the hotend. Flat face aligned with front face of the hot block.
    • Fit the Hotend Adapter to the top of the hotend.

    • Flat face aligned with front face of the hot block.

    • Check the mounting holes alignment.

  4. Use 2 M3x20mm screws supplied with the kit (the washers are optional but we do recommend them). Pair screws and washers.
    • Use 2 M3x20mm screws supplied with the kit (the washers are optional but we do recommend them).

    • Pair screws and washers.

    • Insert each pair in a mounting hole.

  5. This is a very important step to improve the work quality of the existing hotend. Insert the Capricorn tube into the adapter. Push it all the way down. Press it straight.
    • This is a very important step to improve the work quality of the existing hotend.

    • Insert the Capricorn tube into the adapter.

    • Push it all the way down. Press it straight.

    • Insert the 3D printed fixture to guide your cut.

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

  6. Push the fixture all the way until it is blocked by the hotend adapter. Unscrew the nozzle a full turn before inserting the Capricorn tube. Tuck the Capricorn in again to make sure it is all the way down the hotend.
    • Push the fixture all the way until it is blocked by the hotend adapter.

    • Unscrew the nozzle a full turn before inserting the Capricorn tube.

    • 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.

  7. From the Ender-5 you will re-use both fans: Front (Axial) Fan
    • From the Ender-5 you will re-use both fans:

    • Front (Axial) Fan

    • Side (Radial) Fan

    • Check the wiring and manage the cables on both.

    • Use some drops of hot glue to give the contacts more stability in case you feel they can break.

  8. 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.

  9. 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.

  10. 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.
    • 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.

    • No need to tighten. Just push the screw down.

  11. 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.

  12. Cut the 3 zip-ties holding the main cable and tube together. Cut the 3 zip-ties holding the main cable and tube together. Cut the 3 zip-ties holding the main cable and tube together.
    • Cut the 3 zip-ties holding the main cable and tube together.

  13. Pull the cable sleeve away to prepare the DDX placement on the carriage. Pull the cable sleeve away to prepare the DDX placement on the carriage.
    • Pull the cable sleeve away to prepare the DDX placement on the carriage.

  14. 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 Guide the cables through the groove mounts.
    • 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

    • Guide the cables through the groove mounts.

  15. 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.
    • 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.

  16. During this step mind the cable management. Push the DDX against the carriage by fitting the mounting holes against the mounting rods. Push the DDX against the carriage by fitting the mounting holes against the mounting rods.
    • During this step mind the cable management.

    • Push the DDX against the carriage by fitting the mounting holes against the mounting rods.

  17. Keep the DDX vertically aligned Secure the two mounting screws, do not fully tighten. Make sure the fan cables are loose on the side of the DDX.
    • Keep the DDX vertically aligned

    • Secure the two mounting screws, do not fully tighten.

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

  18. The DDX Adapter Set for Ender-3  includes: SLS printed fan shroud. Fit the fan shroud on the bottom of the side fan.
    • The DDX Adapter Set for Ender-3 includes:

    • SLS printed fan shroud.

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

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

    • Use the screw to lock the shroud in place.

  19. 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 one of the short screws stripped from the printer that was fastening the fan to hold one corner.

  20. Use the longest screw stripped from the printer to hold the remaining corner. Check if the SLS Fan Holder is well tight, but don't tighten it too much. and the slider is pointing down as shown in the picture.
    • Use the longest screw stripped from the printer to hold the remaining corner.

    • Check if the SLS Fan Holder is well tight, but don't tighten it too much.

    • and the slider is pointing down as shown in the picture.

  21. 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.

  22. 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.

  23. 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.

  24. 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.

  25. 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 and stepper motor cable to the groove and guide them 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 and stepper motor cable to the groove and guide them through the zip-tie.

    • Lock the zip-tie but do not fully tighten it yet.

  26. Check all the cables is inside the groove. Push the DDX against the carriage without pinching the cables. Tighten the mounting screws to fit the DDX to the carriage until the extruder are faced to the carriage are are mounted solid.
    • Check all the cables is inside the groove.

    • Push the DDX against the carriage without pinching the cables.

    • Tighten the mounting screws to fit the DDX to the carriage until the extruder are faced to the carriage are are mounted solid.

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

  27. The front fan will be mounted using these 3 threaded metal inserts. 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.
    • The front fan will be mounted using these 3 threaded metal inserts.

    • 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.

    • Insert the screws that includes in the DDX in the respective positions

    • Tighten the screws without forcing the insert.

  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 nice aligned with the DDX housing. Lower the cable sleeve to be under the zip-tie.
    • 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 nice aligned with the DDX housing.

    • Lower the cable sleeve to be under the zip-tie.

    • Stretch the motor cable to fit to the groove.

    • Tighten the zip-tie.

  29. We supply 60cm of PTFE tube with the upgrade kit that could be used, or use the standard PTFE tube coming with the printer. Depending how you want to manage the filament feeding, you will need to cut the original or the one we send.
    • We supply 60cm of PTFE tube with the upgrade kit that could be used, or use the standard PTFE tube coming with the printer.

    • Depending how you want to manage the filament feeding, you will need to cut the original or the one we send.

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

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

  30. 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 it to the PTFE tube.

    • Choose the distance from the clip to the DDX, from about 4 to 15 cm away from the push-fit.

  31. Place the second clip somewhere between the first and the original extruder holder. Place the second clip somewhere between the first and the original extruder holder.
    • Place the second clip somewhere between the first and the original extruder holder.

  32. Use the 2.0mm Hex Key. Unscrew this to remove the floating hinge. Hold the assembly before you remove it.
    • Use the 2.0mm Hex Key.

    • Unscrew this to remove the floating hinge.

    • Hold the assembly before you remove it.

    • Take the hinge assembly away.

  33. Use the 1.5m Hex Key Remove one set screw. Remove second set screw.
    • Use the 1.5m Hex Key

    • Remove one set screw.

    • Remove second set screw.

    • Take the drive gear out.

  34. Push the push-fit collar down. Take the PTFE tube out.
    • Push the push-fit collar down.

    • Take the PTFE tube out.

  35. Push the carriage the furthest away possible from the original extruder. Aligning cable and tube together, mark the point where you may cut the PTFE tube. Use the Hobby Knife and Capricorn Cutting Fixture.
    • Push the carriage the furthest away possible from the original extruder.

    • Aligning cable and tube together, mark the point where you may cut the PTFE tube.

    • Use the Hobby Knife and Capricorn Cutting Fixture.

    • Cut the tube straight, where you put your marking.

  36. Insert the PTFE tube back into the push-fit. Insert the PTFE tube back into the push-fit.
    • Insert the PTFE tube back into the push-fit.

  37. Take the motor connector from the original extrusion motor. Manage the Stepper Motor extension cable to reach the original connector. Plug them together.
    • Take the motor connector from the original extrusion motor.

    • Manage the Stepper Motor extension cable to reach the original connector.

    • Plug them together.

  38. Place the second cable clip closer or further away from the first clip. Use a zip-tie to hold main cable, stepper motor cable, and tube together. Use a second zip-tie to hold the cables together inbetween cable clips.
    • Place the second cable clip closer or further away from the first clip.

    • Use a zip-tie to hold main cable, stepper motor cable, and tube together.

    • Use a second zip-tie to hold the cables together inbetween cable clips.

  39. Trim all zip-ties ends. Trim all zip-ties ends. Trim all zip-ties ends.
    • Trim all zip-ties ends.

  40. Give the belt some slack so the end can reach the carriage. Fold the belt tip. Twist it into place, so the metal terminal stands to the front of the carriage.
    • Give the belt some slack so the end can reach the carriage.

    • Fold the belt tip.

    • Twist it into place, so the metal terminal stands to the front of the carriage.

  41. Use the 3.0mm Hex Key. Unscrew and remove the belt tensioner form the frame. Place the belt around the belt tensioner.
    • Use the 3.0mm Hex Key.

    • Unscrew and remove the belt tensioner form the frame.

    • Place the belt around the belt tensioner.

  42. Put the belt tensioner back in the frame. Stretch the belt as much as you can. Tighten one screw to lock it in position.
    • Put the belt tensioner back in the frame.

    • Stretch the belt as much as you can.

    • Tighten one screw to lock it in position.

  43. Tighten the next screw. Finishing installing the belt by tightly screwing both screws. Finishing installing the belt by tightly screwing both screws.
    • Tighten the next screw.

    • Finishing installing the belt by tightly screwing both screws.

  44. Load some filament up to the DDX. Insert the thumbscrew into the hinge. When tightening a screw onto a metal threaded insert use at most 0.4Nm torque.
    • Load some filament up to the DDX.

    • Insert the thumbscrew into the hinge.

    • 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.

    • Tighten the Thumbscrew:

    • tighten it all the way in;

    • Loosen 1 to 2 full turns to use hard filament;

    • Loosen 3 to 4 full turns to use soft filament (flexible).

    • Heat the nozzle up to temperature and finish tightening it before continuing.

    • 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

  45. 2 STEPS UNTIL YOU ARE READY 2 PRINT
    • 2 STEPS UNTIL YOU ARE READY 2 PRINT

    • Perform a bed leveling.

    • After completing this guide you should move on to the following guide:

    • 00. Changing Machine Settings

Conclusion

The installation is almost done.

2 things are missing before you are ready to print:

  1. Perform a bed levelling.
  2. Change The Machine Settings using Cura.

Nuno Santiago

Member since: 04/02/2019

37 Guides authored

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