Geared Servo Direct Extruder

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Introduction

Direct drive and bowden extruder both have it's own advantage. Bowden extruder can be designed to be very light weight resulting in great print quality at higher print speed than direct drive extruder. Direct drive extruder, on the other hand, can handle flexible filament like TPU or TPE better than bowden extruder.

The major disadvantage of direct drive extruder is weight of the stepper motor. This weight will cause ringing in the print when printing at high speed.

To minimize the weight of the direct drive extruder, I've used a light weight geared servo motor instead.

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Servo Motor Choice

I had to overcome a few challenges before I managed to get to an acceptable print quality. There were mechanical, heat and software issues.

The first mechanical issue I had to deal with is the motor drive shaft diameter. Most of the extruder drive