I do like that now I have the ability to change nozzle size without messing with the thermocouple.

Agreed! And the insulation too. I have always been a sucker for modular designs anyway.

Be sure to post back here if you find anything new.

Time to just leave well enough alone, but I do like that now I have the ability to change nozzle size without messing with the thermocouple.

I will try ABS in a few days, and see how it works....

That's cool that Filastruder seems to work well with all sorts of plastics now, and up to 3mm..!!

I am now wondering what will happen if the thermocouple gets moved to the end nozzle...

If you move the thermocouple farther away from the heater, then I would think that would make the barrel hotter, or at the very least it would cause the temperature to fluctuate more. I don't know much about thermodynamics, just a guess.

5-maybe 6 inches/Min.
2.85 ~ 2.86 mm.----------real good tolerance.
PLA
I would say that there is also a bit less duty cycle on the heater.

I like having the melt filter back in.
I don't have a clue to what will happen with ABS, but, it shouldn't be a big deal.

As you know, even the smallest changes will change the thermal properties of everything.......

I am now wondering what will happen if the thermocouple gets moved to the end nozzle...

How's the output rate and diameter tolerance looking relative to your previous solution?

Drill and tap 1/2" nozzle with melt filter to 1/4 NPT.
Install 1/4 X 1/8 steel male-female adapter
then install 1/8" Brass plug drilled out to filament size.
Insulate all the way down to tip of brass nozzle.
Use a aluminum can heat shield with hole in the bottom, and adjust according to how much tip cooling you need.
No Teflon tape.

Tighten all fittings after a good heat-up

but, first use a 3/4 X 1/2 brass female adapter, then 1/2 X 1/4 steel female adapter to minimize heat conductance, then a drilled 1/4 brass plug for a nozzle. That way, everything is easily drilled.

There are no 3/4" parts on a Filastruder. Everything is 1/2" NPT. Just don't want folks to buy the wrong thing.

Only remaining data is an output speed report. We know the normal nozzle did 1.75mm filament at 24"/min. 3mm filament has 2.93 times the area, so I'd expect ~8"/min at 3mm if the nozzle isn't affecting anything.

8 was a good guess. It is averaging exactly 8" /minute.

I'll try to explore this. None of my machines use 3mm so I haven't had much need for 3mm, but it sounds like this might be useful for folks doing non-ABS materials at 3mm.

Thank you for sharing, josh/rich! If others have questions, I'll point them towards this thread so they can try it out and report back.

Steel is more of a pain to machine, slower at least and goes through tooling faster. Would be best to keep the melt filter geometry on the brass bit.