Even though the core function of a 3d Printer Extruder is simply to feed filament into the hotend, the market offers a diverse array of designs, each with unique characteristics. From basic single-gear setups seen on entry-level Ender printers to advanced configurations featuring dual gears, planetary gearboxes, and even belt-driven mechanisms, the options can be overwhelming. These extruders are powered by various motors, ranging from compact steppers to larger ones, sometimes incorporating gear reductions for enhanced torque.
Driven by curiosity and the practical needs of demanding 3D printing applications, I’ve spent considerable time testing a collection of these extruders. My goal was to rigorously evaluate their pushing force and extrusion consistency. Why undertake such a comparison? For a long time, I’ve been exploring the possibilities of small-scale injection molding using 3D printers. This ambitious project, and similar advanced applications, necessitates an extruder capable of generating significant pressure to effectively inject molten material into intricate mold cavities.
However, the demand for robust extruders extends beyond niche projects like 3D printer injection molding. The rapid evolution of 3D printer kinematics towards faster printing speeds requires extruders that can deliver filament at a high and consistent rate. Conversely, the extruder, often positioned as a heavier component on the hotend carriage, can limit achievable accelerations. Therefore, an ideal 3D printer extruder needs to strike a balance between powerful filament feeding and lightweight design.
A Lineup of Tested Extruders (Affiliate Links Provided)
To provide a comprehensive comparison, I tested a range of popular and high-performance extruders available in the market. Here’s the list of models included in my evaluation:
- Bondtech BMG: https://geni.us/oUch
- E3D Hemera: https://geni.us/6lV8
- E3D Hemera XS: https://geni.us/1bHnP
- Orbiter 2.0: https://geni.us/A9STI
- Mellow Cannon (new version): https://geni.us/6VGL
- Bondtech LGX: https://geni.us/xrTN
- Dropeffect OmniaDrop (V3): https://geni.us/7dMS9h
- Dyze Xtruder Pro: https://geni.us/fcr8l5h
- Proper Extruder: https://geni.us/DlA6
- OMG V2 Extruder: https://geni.us/vGJG
Setting Up the Extruder Test Bench
The methodology for testing these 3D printer extruders was designed to be straightforward, drawing inspiration from previous work by industry experts like Adam from Vector3D and Thomas Sanladerer. Each extruder was mounted onto a custom-built frame. Filament was then guided from the extruder into a standalone hotend assembly positioned below. Crucially, a load cell was placed beneath the hotend.
Alt text: Detailed view of the 3D printer extruder test setup, highlighting the load cell positioned beneath the hotend to measure extrusion force.
By isolating the hotend and extruder, any force generated when the filament was pushed through the nozzle was directly measured by the load cell. This force data was sampled at a rate of 10 times per second using an Arduino microcontroller, allowing for precise and real-time force measurement.
Initially, I considered conducting these tests directly on my extensively modified Ender-3 3D printer, which features a tool plate change system from WhamBam. However, the extrusion forces generated proved to be so substantial that they caused deformation in the Ender-3’s frame. This quickly led to the creation of a dedicated wooden test rig, meticulously CNC routed on my Mekanika EVO CNC router, providing a stable and robust platform for high-force extruder testing.
