VORON 2 User manual

GALILEO 2 EXTRUDER
Planetary power for your gardening-tool-built space shuttle.
VERSION 25SEPT2023
VORON

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2
Introduction 03
Galileo 2 Introduction 07
Configuration Requirements 08
Hardware References 10
Heatset Prep 13
Front Body 19
Gearbox Assembly 25
G2 Module 29
Rear Body 39
2
TABLE OF CONTENTS

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3D PRINTING PROCESS
Fused Deposition Modeling (FDM)
INFILL TYPE
Grid, Gyroid, Honeycomb, Triangle or Cubic
MATERIAL
ABS/ASA
INFILL PERCENTAGE
Recommended: 40%
LAYER HEIGHT
Recommended: 0.2mm
WALL COUNT
Recommended: 4
EXTRUSION WIDTH
Recommended: Forced 0.4mm
SOLID TOP/BOTTOM LAYERS
Recommended: 5
3
PART PRINTING GUIDELINES
Galileo 2 follows the Voron Team standards. The Voron Team has provided the following print guidelines for you
to follow in order to have the best chance at success with your parts. There are often questions about
substituting materials or changing printing standards, but we recommend you follow these.
INTRODUCTION

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FILE NAMING
By this time you should have already downloaded the STL files from the Galileo 2 GitHub repository.
You might have noticed that we have used the Voron standard naming convention for the files.
This is how to use them.
PRIMARY COLOR
front_body_ECAS_coupler.stl
These files will have nothing at the
start of the filename.
ACCENT COLOR
[a]_front_bearing_holder.stl
We have added “[a]” to the front of any
STL file that is intended to be printed
with accent color.
INTRODUCTION

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INTRODUCTION
55
HOW TO GET HELP
If you need assembly assistance, we’re here to help. Head on over to the Voron Discord group and post your questions.
This is our primary medium to help Voron Users and we have a great community that can help you out if you get stuck.
https://discord.gg/voron
https://forum.vorondesign.com

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INTRODUCTION
66
REPORTING AN ISSUE
Should you find an issue in the documentation or have a suggestion for an improvement please consider opening
an issue on GitHub (https://github.com/JaredC01/Galileo2/issues). When raising an issue please include the relevant
page numbers and a short description; annotated screenshots are also very welcome. We periodically update the
manual based on the feedback we get.
https://github.com/JaredC01/Galileo2

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INTRODUCTION - GALILEO EXTRUDER
77
WHAT IS GALILEO?
Galileo is a series of planetary-geared projects designed for use in Voron printers designed by JaredC01.
This document covers Galileo 2, or G2, which has an incredible 9:1 gear ratio in a custom-designed
planetary gearbox. This manual covers the Galileo 2 Extruder, or G2E, specifically. There are also other
G2-based projects, such a G2Z drives and a standalone extruder design, which will be covered in
separate manuals.
WHAT BIG GEARS YOU HAVE!
In addition to the planetary gear reduction, G2E also features a custom 16mm RNC-coated filament drive
gear. This means more grip on the filament, helping to minimize filament slip and maximize extruder
output.
DROP IN REPLACEMENT FOR CW2
The G2E assembly is already “stealthed” so it aesthetically matches Clockwork 2, and with a few
configuration tweaks, drops right in on a Stealthburner MGN12 Toolhead. This makes it compatible with
Voron Tap as well as the standard inductive probe carriages.

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CONFIGURATION REQUIREMENTS
88
G2E CONFIGURATION
You must update both the gear_ratio and rotation_distance in your Klipper configuration and do a standard
extruder calibration after installing the Galileo 2 Extruder. Additionally, your run_current will need to be updated.
[extruder]
rotation_distance: 47.088
gear_ratio: 9:1
microsteps: 16
[tmc2209 extruder]
run_current: 0.6

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EXPLODED DIAGRAM
99
FOR REFERENCE ONLY
If yours explodes and ends up looking like this, you may have
a problem. Please ask for help.

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HARDWARE - REFERENCES
1010
SOCKET HEAD CAP SCREW (SHCS)
Metric fastener with a cylindrical head
and hex drive. The most common
fastener used on the Voron.
ISO 4762
FLAT HEAD COUNTERSUNK SCREW (FHCS)
Metric fastener with a cone shaped head
and a flat top.
ISO 10642
HEAT SET INSERT
Heat inserts with a soldering tip so that
they melt the plastic when installed.
As the plastic cools, it solidifies around
the knurls and ridges on the insert for
excellent resistance to both torque and
pull-out.
EXTRUDER THUMBSCREW
Spring will be stiff
MR148 BEARING
Main shaft support
MR115 BEARING
Planetary and idlers

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HARDWARE - REFERENCES
1111
PLANETARY GEAR
31-Tooth MJF Gear
GALILEO 2 EXTRUDER GEAR
RNC-Coated 16mm Drive Gear
RING GEAR HOUSING
72-Tooth MJF Housing
PLANETARY CARRIER SHAFT
Aluminum Carrier
ECAS fitting
You won’t need the black rubber
part on the bottom
NEMA 14 PANCAKE STEPPER
9T, 20mm

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HARDWARE - REFERENCES
1212
PIN
16mm x 5mm OD

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HEATSET PREP - FRONT BODY
1414
Heat Set Insert
HEAT SET INSERTS
This design relies on heat set inserts. Make sure you have
the proper inserts (check the hardware reference for a
close-up picture, and the BOM for dimensions).
If you’ve never worked with heat set inserts before,
we recommend you watch the linked guide.
https://voron.link/m5ybt4d

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HEATSET PREP - FRONT BODY
1515
Heat Set Insert
THAT LITTLE GUY?
Don’t forget the heatset in the idler bearing cover,
which is also part of the front body assembly.

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HEATSET PREP - G2 MODULE
1616
Heat Set Insert

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HEATSET PREP - REAR BODY
1717
YES..MORE HEAT SETS
Just when your your iron timed out
and shut off, we found another.
Heat Set Insert

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HEATSET PREP - REAR BODY
1818
GOT CHAINS?
Make sure to print the version that matches your chains—
some take two screws (shown), some take three.
Heat Set Insert

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FRONT BODY - ASSEMBLY
2020
PUT A PIN IN IT
Install the first of the two pins included with the kit into
the hexagonal hole in the front body until it’s fully
seated into the housing. This pin will hold the idler
bearing opposite the drive gear in G2 extruder design.
5x16 Pin