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ERCF Thumper Blocks (beta)

Table of Contents

NOTE: This is a work-in-progress.

The design has performed very well so far, but it's still going to change as we test and iterate. This project is based off the mature Triple-Decky design but some significant changes have been made which may affect the overall performance. Please keep this in mind if you decide to use Thumper.

Credit:

This is based heavily off the fantastic Triple-Decky project. I've made some improvements based on my own experience and needs, but the core design can be traced back to the original. Thumper Blocks would not exist without the great work of gneu42 or any of the testers/contributors on that project.

What is it?

Thumper Blocks are 3-level filament blocks for the ERCF. Their job is threefold:

  1. Stop filament from moving in or out of the block when not in use
  2. Give solid grip to the gear motor when loading/unloading filament
  3. Provide a low-friction path for filament to move through when the main extruder has taken over

ERCF Requirements

  • Sturdy Bunny ERCF platform
  • Springy selector cart
  • A buffer such as piKa is very strongly recommended. This isn't just for Thumper - a buffer will improve your load/unload reliability with any filament block
  • Happy Hare is very strongly recommended. It's currently in closed beta, but it allows the use of a 3-position servo which is required for Thumper

Differences compared to Triple-Decky

  • Shaves 1.75mm off the width of each block (on Thinner model)
    • This allows the blocks to fit existing hardware and kits without modification or omitting a filament block
    • If you're already set up for Triple-Decky, it reclaims 10.5mm for every 6 blocks. With this, you can add things like a dedicated bypass block
  • Uses an M4 nut for the filament brake instead of a printed part (low friction) or a grub screw (uncommon part)
    • Subjectively improves the assembly process by having a one-piece brake design
  • Removes the need for supports on all parts except the tophat for less post-processing
  • Allows for the use of 1 pair of magnets
  • Lets you use N35 magnets instead of N52, but stronger is still better if you have them
  • Adds features to help with alignment on the 2020 extrusion
  • Streamlines filament path for both initial feeding and endless-spool mode
  • Updates block tolerances for easier assembly
  • Improves tolerances on the latch mechanism

What hasn't changed

  • Triple-Decky's filament tags will fit in Thumper
  • Removes the need for standalone bearing blocks by integrating bearings into filament blocks
  • The general look, feel, and assembly is very similar to Triple-Decky

Which Block?

Thicker

  • The official block of the ERCF v2 spec
  • Has width compatibility with Triple-Decky so accessories (such as the ERCT filament buffer) will fit
  • Use this if you're using ERCF v2 hardware OR you want to upgrade a v1 to an offical v2 but you don't mind losing a filament block

Thinner

  • 1.75mm thinner per-block than the Thicker model
  • Does not remove a block when using ERCF v1 hardware
  • Does not conform to the ERCF v2 spec - the filament bypass and some accessories will not fit
  • Use this if you're on ERCF v1 hardware and you don't want to lose a filament block BUT you don't mind potentially losing compatibility with ERCFv2 accessories

BOM

Hardware

This is per-block unless otherwise noted. I've added (unchanged) to parts that are the same as Triple-Decky.

  • 1x ECAS fitting (unchanged)
  • 1x M3x12mm SHCS for latch (unchanged)
  • 1x BMG driven gear and idler assembly (unchanged)
  • 2x 6x3mm magnets (unchanged)
  • 1x M3x8mm SHCS and 1x M3 T-nut for fastening to extrusion (unchanged)
  • 1x M4 nut for filament brake

Additionally, every 3rd block will need 1x MR85ZZ bearing (unchanged)

Printed Parts

These are made to be printed in ABS and friends (including ASA) and do not require additional shrinkage compensation, just like the main ERCF files.

  • 1x Springy servo arm for your servo of choice
    • NOTE: I've included a backup in this repository just in case, but you should prefer to use the files from Springy
  • 1x every file in the STL folder for each block you want to make
    • NOTE: files are made to be printed in their default orientation and without additional supports

Assembly