NeoFusion V3 - High Flow Direct Drive Hotend for Ender 3 Neo Series

NeoFusion V3

This is a hotend I designed for my Ender 3 V2 Neo. The goal here was to keep it compact, lightweight and aim for high-speed printing. I have printed this hotend and tested fitment, however I did not complete the installation because I changed directions on my project.

_To complete this modification, you will need to dig into the extruder wiring and it will require firmware modifications to utilize the high-temperature hotend. At this time, my suggestion is either to use Mriscoc firmware or upgrade to Klipper._

Here are some of the highlights:

* Ender 3 V3 SE/KE Ceramic Hotend with Unicorn Nozzle

* Creality K1 Direct Drive Extruder

* High-Flow CPAP Cooling Duct, CFD Developed

* Integrated CR-Touch Mount

_Note: Because all the components are fully integrated to a single mounting block, this design may fit other hotend carriages with 14mm spacing. You will have to check for clearances though._

Printing the parts

I always try to design my parts to minimize the need for supports. However the CPAP duct will require some on the upper neck. Otherwise, printing is pretty straight-forward with 0.2mm layer height. Material choices could be PETG, ASA or ABS.

Hardware

The following hardware is required for assembly:

• M3x5mmx4mm Threaded Inserts (qty 8)
• M3x6mm Socket Cap Screws (qty 8)
• M3x20mm Socket Cap Screws (qty 4)
• 2510 Axial Fan
• M2.5x12mm Socket Cap Screws (qty 4)

Assembly

Assembly should be fairly straight-forward. I had to add a small spacer to the bottom of the K1 extruder because PTFE tube does not fit in the bottom of the extruder to bridge the gap to the hotend, so make sure that is in place before installing the extruder.

• Install all heat-set inserts
• Install the mounting block onto your carriage
• Install CR-Touch onto mounting block
• Install hotend onto mounting block
• Install extruder mounting block on top
• Insert extruder spacer into the extruder mount
• Install the extruder on top
• Install the front duct and 2510 hotend fan.

Notes:

This design moves the nozzle out +14mm in the Y-direction.

The CR-Touch offset is changed from the original Neo. It should be 18.75mm directly behind the nozzle in the Y-direction.

Once again, this setup will require firmware changes and wiring for the extruder. Please look into this before taking on this project.

Feel free to reach out or comment any questions or potential design improvements. I'm happy to help out where I can.