Lightest Runout Sensor

I didn’t like the filament runout sensor that I had purchased early on in my 3D printing days, it was based on the ender style end stop as it seemed to add some resistance. It could get annoying when changing filaments especially when changing filament to a different colour when attempting manual multi-colour prints.

I wanted to put the runout sensor nearer the toolhead so I get to use up more of the filament before the sensor triggers yet keep it lightweight enough so it doesn’t add momentum or add any additional movement while the toolhead moves around at higher speeds.

evolution of design

I didn’t want to be reliant of any hardware like screws or bolts to fit it in order to keep weight down. I even decided to forgo the bowden coupler, resorting to making a tapered hole from 4.28mm and rely on forcing the PTFE tube in so that friction and a not so smooth printed surface to keep it in.

Weighing only 3.66g (with the microswitch inserted) and a hole so I can insert an allen key to keep the sensor inactive when changing filament mid-print (until I’m ready)

Currently going vigorous testing on my mercury one.1 printer and no issues so far!

It’s still a work in progress… but if you have the exact same microswitch, feel free to download it and make one yourself.

Since I did purchase a multi-pack of sensors, which I won’t be needing, I may make a few more and sell them… If there is any interest. If you’re interested get in touch via the contact form and possibly I’d mail you one…