I recently installed a "Direct Extruder System" on my Ender 3 using a 3D printed mount. For the first few minutes it worked fine, but after I looked at it once again, I saw that there's nothing anymore coming out of the nozzle so I directly stopped the print.

I've seen that the filament has broken at the point where it gets into the extruder and the motor just extruded it into the air besides the inlet. Today I've taken apart the extruder, and I saw, that there's quite some filament stuck inside the inlet. So I heated the extruder up, tried to remove the PLA, but even on 230 °C it was hard. I don't know what to do now, and I don't really have the option to buy a new extruder now. Does anyone know what to do? enter image description here enter image description here

  • $\begingroup$ Hi GamesNic, welcome to 3D Printing.SE! Maybe some photos will help clarify what you mean. Which extruder did you print? Did you reuse the old hotend? What hotend do you have. Without such information it would be difficult to answer! Also, I suspect the terminology you use is different than we use. The extruder is the part pushing the filament, the hot end the hot part, the cold end the part above the hotend that gets cooled to prevent heat creeping up to the extruder. Where is the inlet located you talk of? $\endgroup$ – 0scar Jan 16 '20 at 13:48
  • $\begingroup$ First of all, thanks for responding! Sorry, I switched extruder with hotend. Basically, I only changed the driving system. The hotend still is the stock one that came with the ender 3. The only thing I did was to 3D print a mounting part for the extruder motor, that sits directly over the hotend. The inlet is, where the PTFE tube once was. And the stuck filament is right there where the hot part is, not too wide up to the cold end. Pictures are here: drive.google.com/open?id=10ZwX-_mmaOSPfamq6C8Chvshs-Z6q_5f $\endgroup$ – GamesNic Jan 16 '20 at 14:11
  • $\begingroup$ I posted a link to a drive folder in my comment, there you can see the extruder driver and the hotend taken apart. And I'm not able to take any of the filament out, as I said, even on 230 °C the filament is hard, even if I poke it. $\endgroup$ – GamesNic Jan 16 '20 at 14:16
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    $\begingroup$ @Trish, pics added. GamesNic, you're going to either need to heat that hot end with it not mounted to the machine, so that the entire thing heats to 230 so that you can at least take a small drill bit, screw it into the melted plastic then when its cooling, yank it out or buy a new throat. $\endgroup$ – user77232 Jan 16 '20 at 20:46
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    $\begingroup$ I finally did it! I let the thing cool down and poked all of the goo through with a hex bit, it came out in one piece. I also know saw what the problem was: I didn't connect the extruder with a PTFE tube to the hotend, which then made a massive clog inside there. After shortening the tube to the distance between hotend and extruder, everything worked perfectly! Thanks for all the answers :D $\endgroup$ – GamesNic Jan 18 '20 at 11:49

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