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Cyberwizzards Alternative X-end

Introduction
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WARNING: Prototype!

In an attempt to upgrade my Mendel to a MendelMax alike X axis (where the X belt is 90 degrees rotated like the Pruse belt path) I redesigned the X-ends to hold a 22mm trapezoid or ACME nut.
Aditionally, I added a tensioner system in order to be able to modify belt tension on the X axis without abusing the carriage attachment for that.

The goal is to use the original Mendel length of smooth rod. As such the block is a fair bit longer than some of the MendelMax designs I have seen; this allows the tensioner system to be placed on it as well.

Details
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  • Modelled in SolidWorks 2012
  • Uses 2 LM8UU bearings
  • Bearings are clamped down with 2x 3mm screws
  • Rods are clamped down with 2x 4mm screws
  • Uses 4x 608 bearings for the belt path

Why not in OpenSCAD? Because prototyping and fitting things together is a breeze in SW - as soon as I work out the issues with this design I will put up a link to the design with an OpenSCAD version as well.

There are 2 versions of this design, one with nice curves and one with a square base block. The rounded version turned out to be impossible to print in one piece using ABS; splitting it into two halves did not help much.
The normal version is using a square base and has much material removed in an attempt to reduce warping and decrease print times.

Both designs most likely require a heated chamber and/or the use of PLA to print properly; as I only have ABS at the moment and only a heated bed I can not get this to print straight.