Bondtech Prusa I3 MK3S/MK2.5S Mosquito Extruder Upgrade Manual (EXT-KIT-69)

Introduction

This manual provides essential information for the Bondtech Extruder Upgrade Kit (EXT-KIT-69) for Prusa I3 MK3S, MK3S+, and MK2.5S 3D printers. This kit is designed to convert your existing extruder to a Bondtech Mini Geared (BMG) based system, enabling the use of Mosquito hotends and enhancing printing performance.

The upgrade kit includes components necessary for the conversion, featuring a 3:1 gearing ratio for improved precision and resolution, along with optimized geometry for heatsink cooling and a professional SLS 3D printed housing.

Kit Contents

The Bondtech EXT-KIT-69 includes the following components:

• Bondtech BMG-based extruder housing (SLS 3D printed)
• Stepper motor
• Mounting hardware (screws, zip ties)
• Wiring harness
• Bondtech branding sticker

Note: This kit does not include Bondtech drive gears, as these are typically supplied with the original Prusa printer. Additional components required for a complete setup are listed in the "Setup and Installation" section.

Image: Overview of the Bondtech EXT-KIT-69 upgrade kit components, including the extruder assembly, stepper motor, various mounting hardware, and wiring.

Setup and Installation

The installation of the Bondtech EXT-KIT-69 involves disassembling the existing Prusa extruder and replacing it with the Bondtech components. This process requires careful attention to detail and familiarity with 3D printer mechanics.

Required Additional Components (Not Included in this Kit):

• Mosquito Hotend or Mosquito Magnum Hotend: Essential for material flow and compatibility with the new extruder design.
• Boron Nitride Paste: Recommended for proper thermal transfer with the hotend.
• SLS X-Carriage Kit: For enhanced temperature and mechanical resistance. STL files for 3D printing this component are available from Bondtech's resources section.

Installation Resources:

For detailed, step-by-step installation instructions, please refer to the official Bondtech documentation and guides available on their website. These resources provide comprehensive visual aids and instructions specific to your Prusa model.

Visit Bondtech's Official Documentation for Installation Guides

Image: Front view of the Bondtech extruder assembly, showcasing the stepper motor and the main housing with the Bondtech logo.

Image: Rear view of the Bondtech extruder assembly, highlighting the fan mounting area and the honeycomb structure for cooling.

Image: Side view of the Bondtech extruder assembly, showing the filament path and the connection point for the hotend.

Image: The Bondtech extruder upgrade installed on a Prusa i3 MK3S 3D printer, viewed from the front, showing integration with the printer's components.

Image: The Bondtech extruder upgrade installed on a Prusa i3 MK3S 3D printer, viewed from the side, illustrating its compact design and placement.

Operating Principles and Benefits

The Bondtech extruder upgrade utilizes a dual-drive gear system with a 3:1 gearing ratio, providing several operational advantages:

• Increased Push Force: The geared system delivers significantly more force to push the filament, improving reliability with various materials, especially flexible ones.
• Higher Resolution: The gearing allows for finer control over filament extrusion, leading to improved print quality and detail.
• Reduced Heat Creep: Optimized design helps decrease the risk of heat creep, which can cause clogs.
• Improved Filament Feeding: Minimizes filament slipping and deformation, preventing under-extrusion and over-extrusion issues.
• Compatibility: Specifically designed to integrate with Mosquito and Mosquito Magnum hotends, expanding material capabilities.

These features contribute to faster printing speeds and higher quality output from your Prusa 3D printer.

Maintenance

Regular maintenance ensures optimal performance and longevity of your Bondtech extruder. Follow these general guidelines:

• Clean Drive Gears: Periodically inspect and clean the drive gears to remove any accumulated filament dust or debris. A small brush or compressed air can be used.
• Check Filament Path: Ensure the filament path is clear and free of obstructions.
• Inspect Hotend: Regularly check your Mosquito hotend for any signs of clogging or wear. Follow the hotend manufacturer's maintenance recommendations.
• Lubrication: The gears are typically self-lubricating or pre-lubricated. Avoid applying excessive lubricants unless specifically instructed by Bondtech.
• Tighten Fasteners: Periodically check all mounting screws and fasteners to ensure they are secure.

Troubleshooting

This section addresses common issues that may arise with your extruder upgrade.

Common Issues and Solutions:

• Filament Grinding/Skipping:
  • Check for clogs in the hotend or nozzle.
  • Ensure proper tension on the extruder idler arm.
  • Verify print temperature settings are appropriate for the filament.
  • Clean drive gears for debris.
• Under-extrusion:
  • Confirm filament diameter and flow rate settings in your slicer.
  • Check for partial clogs in the hotend.
  • Ensure the extruder motor is receiving sufficient power.
• Over-extrusion:
  • Adjust flow rate settings in your slicer.
  • Verify filament diameter setting.
• No Filament Movement:
  • Check motor connections.
  • Ensure the motor is enabled and receiving commands.
  • Inspect for severe clogs or mechanical obstructions.

For more complex issues, refer to Bondtech's official support resources or community forums.

Specifications

Warranty Information

For detailed warranty terms and conditions, please refer to the official Bondtech website or contact Bondtech customer support directly. Warranty policies typically cover manufacturing defects for a specified period from the date of purchase.

It is recommended to retain your proof of purchase for any warranty claims.

Support and Contact

Should you require further assistance, technical support, or have questions regarding your Bondtech extruder upgrade, please utilize the following resources:

• Official Bondtech Website: www.bondtech.se
• Support Page: Look for a dedicated support or contact section on the Bondtech website for FAQs, troubleshooting guides, and contact forms.
• Community Forums: Engage with the 3D printing community or Bondtech's official forums for peer support and shared experiences.