FrankEnstein 2.0

The Xol we have at home

SchlongkyDong 28/07/2024

Welcome to the Frank 2.0 Toolhead! This highly modular, Ender 3-optimized, and very stable toolhead is the second generation of the FrankEinstein Duct, offering significantly better performance and flexibility. While Frank 1.0 supported only 5015 part cooling, Frank 2.0 supports both 5015 and 4010 fans, along with a wide variety of hotends and extruders. It also supports various probes, and you can choose between the stock V-Wheel plate or upgrade to linear rails. Additionally, nozzle LEDs can enhance your printing experience, and an integrated mount for an ADXL sensor makes it perfect for all the speedy Klipper setups out there.

This design is headache-free.

What does that mean? Well, this design avoids everything that caused troubles and unnecessary headaches with other toolheads in the past. One thing I really dislike is (unnecessary) reprints. Nothing is more annoying than wasting good filament just because you want to upgrade a component. Therefore, Frank 2.0 is very modular, meaning that you only have to swap out the part you want to change. New hotend? Just print a new hotend mount. New extruder? Nothing easier than that! Simply print a new extruder mount. And guess what, everything else stays untouched.

Besides the modular design, Frank 2.0 is also very easy to maintain. The whole toolhead is held in place by just four screws. So if you need to access the Base Plate or the rear of your hotend, clean the nozzle, or whatever else, you can easily remove the toolhead. All the parts interlock so nicely that with the four screws in place, you can even assemble the whole toolhead on your desk and then attach it to the baseplate on the printer without any compromises on stability and rigidity. As an added benefit, if you want to change the extruder, simply remove the two upper screws, and you can take out the entire extruder unit while everything else stays in place on your printer. Nothing falls apart or gets lost. It’s almost too easy, right?

Another main focus when designing Frank 2.0 was compatibility. Due to its modular design, it is very easy to add support for new or changing hardware. Simply remix a part of Frank, and you get new supported hardware—how awesome is that! On the other hand, this also means that the designer (which, unfortunately, is me) has to keep all the bits and parts updated. It’s a lot of work to maintain, so I’m always happy for contributions! I think this is also the right time to give a big thanks to the DoD, especially hawk16zz, who made this release possible, and Wight554 who did a lot of work on the MGN stuff!

What is supported?

Supported Hotends, Extruders and additional Hardware

This section lists all compatible Hotends and Extruder. If you’re missing your hotend or extruder, feel free to post a request for that on my Discord. Let us create the first Fan Duct, that support almost everything! (Please not the Limitations section below)

Hotends

1.  Stock Mk8 
2.  Phaetus - Dragonfly BMS
3.  Phaetus - Dragonfly BMO (with rigid mount)
4.  Phaetus - Dragon (Standard Flow and High Flow)
5. Slice - Mosquito / Mellow Crazy
6. Trianglelab - TR6 (with rigid mount)
7. Creality - Spider Hotend
8. Creality - Spider Pro
9. Creality - Spider V2
10. TwoTrees - TZ V6 (with rigid mount)
11. Haldis - Red Lizard (with stock version)

Extruders

1. Bowden extruders             (stock or any replacement you're using)
2. Annex's - Sherpa Mini        (With adapter also Sherpa Micro)
3. Róbert's - Orbiter V1.x / V2.0
4. Bondtech - LGX Lite
5. :D - Papilio

Hardware

1. BL-Touch and Clones
2. ADXL345-Accelerometer (for Klipper and RepRap) 

What do I have to print?

Frank 2.0 is made out of 4 main components:

The Hotend Mount

The Hotend Mount is the “core” of the toolhead. It is made up of two pieces, a front and a rear half, that hold the hotend in place. Please note that Frank 2.0 does not reuse the original mountings from the V-Wheel plate, which means that some offsets might be different (more about that in the XY probe section). This is to keep Frank 2.0 very modular. No matter what hotend you choose, the nozzle will stay in the same position, meaning that you can keep everything else the same (e.g., fan ducts, probe mounts, and so on). Simply select the folder for the hotend of your choice and put the two parts in your slicer.

Special note: Frank 2.0 uses a 3010 fan by default for the hotend cooling. If you are transitioning from a stock Ender 3 toolhead, you will need to buy a new one. I chose the 3010 for aesthetic and space reasons; the cooling performance is more than sufficient and it helps to keep the toolhead compact. If you don’t want to buy a new fan and prefer to reuse what the Ender provides, there’s a 40mm adapter in the XY extras section.

The Extruder Mount

Another key component is the Extruder Mount. This part attaches on top of the Hotend Mount and provides a place to mount your extruder. It is specifically designed for the extruder you want to use, ensuring perfect mounting patterns for each extruder. This should be fairly self-explanatory.

The Part Cooling Fans

How much cooling do you need and what do you want your Frank to look like? These are the main questions when choosing the correct Part Cooling Fans. The stock Ender 3 toolhead comes with one 4010 fan. You can use that and get a second 4010 fan to create a very small and compact Frank 2.0. If you need even more cooling, you can get two 5015 fans, which will cool your molten plastic like nothing else. In my opinion, the 4010 fans provide more than enough cooling and look fantastic.

The Base Plate

The Base Plate

The entire toolhead is mounted to a custom Base Plate to ensure a modular design, allowing all Ender 3 versions to use the same files for all the parts. You can choose between a Base Plate for the stock V-wheel carriage or a Base Plate for an MGN rail (both MGN 12H and MGN 12C rail types are supported at the time of writing). The benefit of this approach is that all other files remain 100% the same, regardless of whether you’re using the stock carriage or a linear rail. This means if you upgrade to rails at some point, all you need to print are the base plate parts for the linear rail and mount the same Frank on it. It couldn’t be easier.

The linear rail plate requires a new belt and a belt clamp, as the stock mounting options are no longer available with the new toolhead. We tested many custom versions of a belt clamp; some worked better than others, but in the end, we decided to go with a design based on the LH Stinger Clamp (credit link).

Extras

In addition to the main components that will give you a functional Frank 2.0, you can choose the following extras for additional customization. Please note that some of these extras may not be compatible with both base plates. I may add more compatible extras in the future or link user mods; until then, keep an eye on the Discord or send a request there.

4010 Hotend Fan adapter

As mentioned earlier, this part replaces the 3010 fan and routes air from a 4010 fan to the hotend. To install, first attach the adapter where the 3010 fan would go, then mount the 4010 fan onto the adapter. This adapter also provides a new mounting point for the ADXL sensor, as the original mounting on the Hotend Mount will be blocked. Special thanks to Tkaus for improving this part!

Integrated KlackEnder Mount (Rail Only)

As a part of the Belt Clamp Frank natively supports the KlackEnder Probe. The mount can be simply screwed on the belt Clamp.

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Assembly

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