If it's not one thing it's another!

The third post in a row about my extruder breaking, not a good start to the year!

Now that I am making solid test shapes rather than hollow ones the extruder is working a lot harder and all it seems to do is break down. The drive cable started to disintegrate this afternoon, I could hear the strands breaking :-



It was still limping on however when this happened :-



The brass nozzle started to come out of the PTFE heat barrier. This was ironic because it was only yesterday that I said I had not had this problem in a forum discussion. Others have had it happen and the collective wisdom is to use a pipe clip round the end of the PTFE to secure it.

And the JB Weld which insulates the heater wire has turned to dust :-




So some rebuilding to do!

Running repairs

No sooner than I had fixed my heater, the extruder motor failed!

I bodged the heater connection by putting some more solder on it. It's not a permanent solution because the solder is molten while the heater is on so it slowly oxidizes away. The last time bodged it that way it lasted six months though. It really needs a crimped connection.

The GM3 motor failed by running slowly, getting very hot and drawing lots of current. It eventually caused the protected MOSFET that is driving it to shut down. Opening it up soon revealed how it had failed :-



It has two pairs of copper brushes. Three of them have holes worn right through and the fourth has broken off. Its stub was touching the wrong side of the commutator, causing a short.

More expensive motors have carbon blocks on the end of arms which can wear down a lot further before they fail. Bigger motors have spring loaded carbon rods. The gearbox shows no sign of wear so it is let down by the cheap motor.

This motor is not really up to the job of driving the extruder. It is being severely abused by running it from 12V PWM when it is only rated at 6V. I anticipated it would not last long and ordered a spare when I bought it. I fitted that and HydraRaptor is up and running again. Curiously the second motor seems a lot quieter than the first.

At some point I think I will upgrade to a stepper motor. They are more expensive but, as long as you don't load the bearings, they last virtually forever. In the long run they probably work out cheaper and I can also dispense with the shaft encoder and the interference suppressor.

Wear and tear

My extruder's heater went open circuit so I removed the heat shield to have a look at it. I have actually run it for many hours now and have extruded quite a lot of HDPE. I have about 200g of extruded test objects and scrap which represents about 13 hours operation. I only recently started saving my scrap so I must have extruded a lot more. The 2.5Kg reel of HDPE is noticeably smaller.

The heater has also run for a lot longer than the extruder has been extruding. I got fed up of waiting for it to warm up at the start of each run so my host software leaves it on. I keep meaning to put a timeout in the firmware to turn it off when there hasn't been any Ethernet messages for a while as I have left it on for long periods a few times.

The extruder is starting to show some signs of aging. The plastic shield which keeps the fan draft away from the nozzle looked like this when I made it :-



But now it looks like this :-



The nozzle itself now looks like this :-



The JBWeld that surrounds the heater wire has gone very dark and has several cracks in it. One of the heater connections broke off in a previous accident so I dug it out and joined a piece of copper wire by squeezing it tight and soldering it. There is now no sign of the solder which is why it has gone open circuit.

The black stuff which looks like bitumen must be slow cooked HDPE. I am surprised that long term heating to 240°C causes it to decompose. I don't know if the white surface on the shield is just due to its surface melting a bit or whether something boiled off the nozzle and condensed onto it or reacted with it.

Even the high temp insulation over the thermistor wires is starting to look a bit sad!

I also noticed that the steel wire that forms the flexible drive coupling is starting to break up. A couple of strands have snapped and there is a pile of black dust on top of the pump shell.



The heater connection should be easy to fix. I have a few planned improvements to make to the extruder but I will wait till parts wear out before replacing them with better ones to get the most use of it.