Project Dashboard Accessories and Upgrades LulzBot Mini Aerostruder Tool Head Installation Workflow

1 Getting Started

Follow the instructions below to quickly install your LulzBot Mini Aerostruder on a LulzBot Mini 3D Printer.

LulzBot Mini Aerostruder

2 Included Materials

(1) LulzBot Mini Aerostruder Tool Head (Fully Assembled)

(1) PVA gluestick 0.77 oz

(1) Metric hex keys (2.5 mm, 4.0 mm)

Included Materials

3 Additional Items Required

You will also need

  • Scissors or wire cutters for cutting zip ties
  • LulzBot Mini desktop 3D printer
  • USB cable included with your LulzBot Mini
  • GNU/Linux/Windows/Mac-based computer
Additional Items Required

4 Position the Z-Axis

Power on your LulzBot Mini 3D Printer.

Connect your printer to your computer using the USB cable.

Press the Print Monitor control tab in the top right of Cura LulzBot Edition.

Verify USB Device Available, as shown in image.

Under "Manual Control" click Connect.

Click the home icon below "Position Z".

Click Print Monitor Control tab
USB device available
Click Connect
Click the home icon below "Position Z"

5 Power Off Your LulzBot 3D Printer

Power off and unplug the power cord from the rear of the printer.

Unplug the USB cable from the front of the printer.

Power off your Mini

6 Remove Connector Cover

Using your 2.5mm driver, unscrew the two M3 screws that secure the connector cover on the X-axis carriage, located on the top of the cover.

Using the scissors, cut the two zip ties that secure the harness to the carriage.

Lift the connector away from the X-axis carriage.

Unplug the tool head connector from the wiring harness.

Unscrew 2 M3 screws ontop of Connector Cover
Cut zip ties securing the harness to carriage
Unplug the tool head connector from the wiring harness

7 Remove Existing Tool Head

The tool head is attached with three screws. The print surface can be damaged if the tool head is allowed to fall onto the print surface. With one hand, support the tool head while following removal steps below.

Using the 4mm hex key, unscrew the three M5 screws securing the tool head to the X-axis carriage. Remove the bottom screw first, followed by the remaining two screws.

Remove the tool head from the printer by lifting the tool head away from the printer.

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

Remove bottom screw first
Remove screws while holding tool head

8 Mount the New Tool Head

Press the Aerostruder onto the X-axis carriage, aligning the tab with the cutout on the back of the new tool head.

Secure it to the X-axis carriage by loosely screwing in the top two screws. Leave the top two screws loose.

Install the last screw into the bottom of the X-axis carriage and fully tighten.

Tighten the top two screws.

Press Aerostruder onto X-axis aligning tab with cutout

9 Plug in Tool Head

Pull foam off of 16-pin connector piece.

Connect the two 16-pin connectors, making sure to match them based on the pins in the connector.

Connect the two 16-pin connectors by aligning pins in the connector

10 Mount Connector Cover

Cover the connector with the connector cover and attach it to the X-axis carriage using the two M3 screws and the 2.5 mm hex key.

Channel the wires together going to down the vertical pathway on the cover mount, and try not to pinch any of the wires when securing the cover. Slide down carefully into place, and hold while screwing in.

Screw in cover using two M3 screws

11 Install or Update Cura LulzBot Edition

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.

Cura LulzBot Edition is available from

Plug in your LulzBot Mini 3D printer to the power supply and power on your 3D printer.

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

Open Cura LulzBot Edition.

Open Cura LulzBot Edition

12 Setup New Tool Head in Cura

Power on the printer.

Select Settings dropdown > Printer > Add Printer

Select LulzBot Mini Aerostruder, and click Add Printer.

Select Finish.

Add Printer dropdown
Add Printer
Select Finish

13 Update Firmware on Printer

Power on the printer.

Select Settings dropdown > Printer > Manage Printers

Confirm the LulzBot Mini Aerostruder is selected, and click Upgrade Firmware.

Select Automatically Update Firmware.

Settings > Printer > Manage Printers
Upgrade firmware
Select Automatically Update Firmware

14 Set Hotend Temperature

Select Print Monitor Control Tab in top right corner.

Click Connect.

Insert temperature as 205°C for Extruder 1. 205°C is the removal/print temperature for PLA (factory filament left in the tool head from calibration).

Select Heat Extruder.

Select Print Monitor Control Tab
Click Connect
Insert temperature as 205, select Heat Extruder

15 Remove Factory Filament

Note: Always heat the hot end to extrusion temperature before attempting to remove filament as this will prevent clogging or jamming in the filament chamber.

Once hot end has reached the extrusion temperature of 205, remove test filament used during factory calibration by manually winding gear as shown in image. You can also do this by entering 60 for the Extrusion amount in Cura and clicking Retract.

Once filament has retracted 60 mm, squeeze idler inwards, and pull the filament out. You may need to loosen the idler slightly by turning the silver idler wheel clockwise.

Tighten the idler by turning the silver idler wheel counter-clockwise if loosened.

Wind gear to retract filament

16 Load Filament

Note: If filament other than PLA is being used, refer to page 35 of the LulzBot Mini User Manual for recommended hot end temperatures. Repeat Step 14, entering in appropriate temperature value within range suggested for chosen filament before loading filament.

Load your filament into Extruder 1. Squeeze the idler arm inward and insert the filament directly downwards.

Rotate the gears by hand as shown in the image to help pull the filament into the tool head.

Purge factory filament by continuing rotating gear by hand as shown in image until extrusion transitions into your filament of choice.

Entry point for filament
Squeeze idler
FIlament inserted
Wind gear as shown to help load and extrude filament

17 Enjoy Printing with your new Aerostruder Tool Head!

You've now finished installation and are ready to start printing with flexible and rigid materials using your LulzBot Mini Aerostruder! Try performing a test print, such as the Rock2pus.

Try out the Rock2pus for your first print!
Done! Take me home