Project Dashboard Accessories and Upgrades LulzBot TAZ Dual Extruder Tool Head v3 Installation Instructions for TAZ 5 Workflow

1 Getting Started

By purchasing a LulzBot TAZ Dual Extruder v3 Tool Head, you're ready to begin combining colors and textures with support material for unique prints that are sure to turn heads. Follow the steps below to install your LulzBot TAZ Dual Extruder v3 Tool Head on your TAZ 5 and explore the possibilities of printing with full geometric freedom.

Note: Be sure you are using the correct OHAI guide! The Dual Extruder v3 installation guide for TAZ 6 users can be found here

LulzBot TAZ Dual v3 Tool Head

2 Included Materials

(1) LulzBot TAZ Dual Extruder v3 Tool Head

(1) Additional spool arm

(1) Feed tube spinner

(1) T-nut holder jig

(1) Idler jig

(1) Machined Z-axis endstop extension (for TAZ 6)

(1) 3D Printed Z-axis endstop extension mount (for TAZ 6)

(1) Dual v3 wiper mount (for TAZ 6)

(4) Wire tie

(4) Low profile bed corners (For TAZ 5)

(1) M5 x 14 socket head cap screw (TAZ 5)

(2) Extension harnesses

(1) M5 washer (black)

(1) Feed tube

(1) Sample amount of PolyDissolve S1 filament

(1) Sample amount of Polylite PLA filament

Included materials

3 Additional Items Required

You will also need

  • Metric hex drivers: 4 mm, 3 mm, 2.5 mm included with your LulzBot TAZ toolkit
  • LulzBot TAZ Desktop 3D Printer
  • USB cable, included with your LulzBot TAZ
  • GNU/Linux, Mac OS X, or Windows-based computer
  • Scissors or wire cutters for cutting zip ties
Other things needed

4 Position the Z-Axis

Let's get started!

4A
Power on your LulzBot TAZ 5 3D Printer.

4B
Home your 3D printer by using the Graphical LCD controller to home the printer.

4C
Raise the Z-axis through the Graphical LCD controller.

4D
Navigate to: Prepare > Move Axis > 1.0 > Z-axis > Change the value to at least 200.

4E
After the Z-axis stops moving, push the X-axis carriage over by hand to the middle of the X axis.

Raise Z-axis, position X-axis

5 Power Off Your LulzBot 3D Printer

5A
Completely power off your LulzBot 3D Printer and unplug the power supply before proceeding.

Power off yout TAZ 3D printer, disconnect the USB cable

6 Remove Bed Fingers

Additional clearance is necessary for the extrusion fan ducts on your new dual extruder.

6A
Remove the four original 3D printed bed corner fingers using a 2.5 mm hex driver.

7 Replace Bed Corners

7A
Using a 2.5 mm hex driver and the screws removed in the previous step, replace the bed corner fingers with the 3D printed lower profile bed corner fingers.

The recessed side of the bed fingers should be facing up.

Remove original bed corners and screw in lower profile bed corners

8 Install Secondary Spool Arm

8A
Loosen the existing spool arm and slide it down about 2 inches (50 mm), and tighten it.

8B
Insert the new T-nut included with your Dual Extruder Tool Head v3 on the same Z-axis vertical frame (the front right extrusion), in the same channel.

8C
Use the M5 screw to install the 3D printed secondary filament spool arm.

8D
Place two spools of filament on the spool arms to ensure they are mounted with sufficient space to rotate during printing.

8E
Attach the secondary filament guide tube included with your new dual extruder, matching the existing feed tube orientation.

Insert T-nut
Spool arm spacing
Spool arm spacing
Attach secondary filament guide tube

9 Connect Secondary Extruder Harness

9A
Unscrew the cap on the second port on top of the electronics box on your LulzBot TAZ 5 3D Printer, then plug in the secondary extruder harness into the uncapped port.

9B
Route the new harness next to existing one on your printer, using wire ties to secure it in the same spots.

9C
Use a zip tie to secure the new secondary extruder harness into the empty harness holder on the top-left side of the x-carriage.

Note: Correct functionality can be tested by giving a command to Extruder 1 in Cura, and then watching to be sure Extruder 1 executes the command on the printer.

Connect secondary extruder harness
Recommended wire-tie locations

10 Remove Existing Tool Head

10A
Unplug the connectors for your current tool head.

10B
With one hand support the tool head and unscrew the single M3 screw securing it to the X-axis carriage.

10C
Remove the tool head from the 3D printer by lifting the tool head up.

Note: In previous versions of our tool heads, the Esteps were listed along the back of the tool heads for the customer to update. For the new v3 tool head however, the Esteps are now set up within the firmware, and no manual updates are required.

Remove original tool head
Support tool head

11 Replace Screw on Tool Head Mount

8A Use a 2.5 mm hex key to remove the screw in the bottom right of the tool head mount, as shown in image.

Note: Tool head mount does not need to be removed from the X-axis carriage, and is shown separately in the image for clarity.

8B Use a 2.5 mm hex key to replace screw with the M3x12 BHCS included with your V3 Dual tool head.

Replace screw on bottom right of tool head mount

12 Mount New Tool Head

11A
Install the Dual Extruder Tool Head v3 by seating it on the X-axis carriage and securing it with the M3 screw that you removed in the previous step.

Screw in tool head

13 Plug in Tool Head

12A
Remove the protective foam from harness.

12B
Connect the primary extruder harness (existing harness) to the right-hand (E2) connection on tool head, taking care to note polarity. Make sure to match connections based on the the pins in the connectors.

Note: Older models may have guide pins in the extruder harness for connecting with a standard tool head. If the pins are not aligning correctly with the Dual Extruder v3 connections, as shown in image, one of the pins may need to be removed. Refer to this Molex Pin Replacement guide, steps 3 and 4, for instructions on removing pins.

12C
Connect the secondary extruder harness (new harness) to the left-hand (E1) connection on tool head, taking care to note polarity. Make sure to match connections based on the the pins in the connectors.

12D
Make sure the connectors are not against any moving parts and tuck into X-axis carriage notches. Verify the connectors are appropriately connected before proceeding.

Remove protective foam
Connect primary extruder harness to right (E2) connection
Connect secondary extruder harness to left (E1) connection
Tool head plugged in

14 Install Cura LulzBot Edition

13A
Install the latest version of Cura LulzBot Edition. It is important to have the LulzBot Edition of Cura, as it has preset machine configuration profiles built into it.

13B
Cura LulzBot Edition is available from http://LulzBot.com/Cura.

13C
Plug in your LulzBot TAZ 3D Printer to the power supply and power on your 3D printer.

13D
Once powered on, connect your 3D printer to your computer using the USB cable.

13E
Open Cura LulzBot Edition.

Open Cura LulzBot Edition

15 Set Up New Tool Head in Cura

14A
Select Settings dropdown > Printer > Add Printer.

14B
Select LulzBot TAZ 5 DualExtruder V3 and click Finish.

Select settings dropdown
Add printer

16 Update Firmware

15A
Power on the printer.

15B
Select Settings dropdown > Printer > Manage Printers.

15C
Confirm the LulzBot TAZ 5 DualExtruder v3 is selected, and click Upgrade Firmware.

NOTE: Follow the instructions displayed on screen and [linked here] to record and restore your Z-axis offset.

Select Settings dropdown, Printer, Manage Printers
Upgrade firmware
Record Z-axis Offset

17 Monitor the Z-axis during first homing movement

16A
To prevent damage to your 3D printer, power it off immediately if the tool head looks like it is on a course to lower into the print surface before triggering the Z end stop.

If the tool head looks like it will prematurely trigger the Z end stop too high above the print bed, adjust the thumb screw lower and restart this process.

The spring and washer can be removed if needed to achieve the proper Z height.

Remove washer and spring if needed

18 Load First Print into Cura

17A
Download test model and load it into Cura.

17B
Adjust the default print settings for filament. On setup, load Polylite PLA and PolyDissolve S1 by following steps below:

17C
Confirm selections for Extruder 1: Extruder 1 tab > Polylite PLA and the Material dropdown > Standard Quality.

17D
Select Extruder 2 tab > PolyDissolve S1 from Material dropdown, and then select the Generate Support box.

Material dropdown for extruder 1
Material dropdown for extruder 2
First Print

19 Switch to Print Monitor Control Tab

18A
In the top-right corner, click the Print Monitor Control Tab button, as shown in the image. Steps 18 and 19 are implemented through this tab's settings.

Print Monitor Control Tab

20 Connect to Printer

19A
Check that Cura LulzBot Edition shows USB devices detected then click on the Connect button.

19B
Wait for message to show Connected via USB.

Available USB devices
Click Connect
USB device connected

21 Set Hot End Temperature

20A
Confirm Extruder 1 is selected in the Select extruder drop down menu, as shown in the image.

20B
Insert temperature as 205°C.

20C
Select Heat Extruder.

20D
Select Extruder 2.

20E
Insert temperature as 220°C.

20F
Select Heat extruder.

Note: If you scroll down, another option is available to assign to temperature values to each extruder, as shown in image. Enter in the same value for each each extruder as shown above, then select Heat extruder.

Temperature values for Select extruder 1
Alternate option for assigning temperature value to extruders

22 Remove Factory Filament

21A
Once extruders reach temperature, remove test filament used during factory calibration.

Note: To remove filament, wind gear counterclockwise for Extruder 1, and clockwise for Extruder 2. OR, you can also squeeze idler inwards, and pull filament out.

Factory filament in tool head
Wind gear as shown to remove filament
Squeeze idler inwards and pull filament out

23 Adjust Idler Tension with Printed Idler Jig

22A
To prevent the filament from stripping, it's important to calibrate both of the idlers before loading in the new filament.

22B
Locate the printed idler jig included with your LulzBot TAZ Dual Extruder v3 Tool Head.
Note: Idler jig is colored black in the kit, but is shown here in green for clarity and ease of visibility.

22C
Insert printed idler jig next to an idler, as shown in the image.

22D
Adjust each idler onto the printed jig one at a time. They should be tightened until the black head of the idler makes contact with the jig. Do not overtighten. The printed jig should be able to slide out easily.

Printed idler jig moving into correct placement
Printed idler jig in place
Tigthen idler onto printed jig

24 Filament Path

23A
In order to keep the Dual Extruder v3 as compact as possible, the filament path was designed differently than on Standard LulzBot Tool Heads. Steps for inserting filament are further detailed below:

text

25 Load Sample Filament

24A
Clip end of filament with scissors to form a slanted point. This will improve the insertion effectiveness of the filament as it reaches the channel.

24B
Load Polylite PLA in Extruder 1 (left), and PolyDissolve S1 in Extruder 2 (right). Slightly pull back on the idler arm and insert the filament from a 45° angle.

24C
Once the filament stops, you may need to wiggle the filament until it slides in farther.

24D
Rotate the gears by hand to help pull the filament into the tool head. Clockwise for Extruder 1, counterclockwise for Extruder 2.

Note: If you're still experiencing difficulty loading the filament, slightly loosen the idler tension by half-turn increments to allow for more space on the filament path. It's possible for the filament to emerge from the back of the extruder during loading, simply remove and try loading again. Make sure the filament end is clipped at an angle to reach the channel.

24E
Purge factory filament by continuing to rotate gears by hand for both extruders, until extrusion transitions into the sample filament. Clockwise for Extruder 1, counterclockwise for Extruder 2.

Clip filament so it forms a pointed angle
Slightly pull on idler arm and insert filament at 45 degree angle
Wiggle filament and push again
Filament path highlighted
Purge remaining factory filament

26 Start Your First Print

25A
Click the Start button.

Click Start in Cura

27 Removed Finished Print

26A
Wait until bed cools to recommended part removal temperature.

26B
Use blue handle knife to lift print off of bed.

Remove test model after bed cools

28 Let Print Sit in Water

27A
We recommend placing the print in water and letting it sit to allow the soluble support filament to loosen and come off naturally. Change water and rinse the printed object every hour or two, depending on the size of the print.

Optional: Structural support may soften after 30 minutes and can be removed using additional tools, such as a tweezer or dentist pick. If not soft enough, print will need to be agitated and water refreshed regularly to further dissolve filament.

Structural support removed

29 Enjoy Unrestricted Printing with Full Geometric Freedom!

You've now finished installation and are ready to explore new territories of 3D printing with your Dual Extruder v3!

Done! Take me home