The SENATE - amS feedEr buttoN And proTEctor for Bambu AMS System

Look at me mom, I used another stupid acronym.

I was not happy with all the AMS Feeder Protector Button things out there, they all had flaws and strengths, including my own previous design. This is my attempt at drawing inspiration from the other AMS Feeder Buttons out there and combining all of their strengths.

Inspiration is mostly taken from:
Bambu AMS Feeder Button by Warpster - I liked how this one snapped on tightly and stayed on.
Hydra AMS PTFE Load Buttons by Humebeam - I like how this one had the larger, wider buttons that are easier to push.
My own previous design - I incorporated an angled hole for the PTFE tube in that design, and it carries on to The SENATE.

Benefits of using The SENATE:

• Protect your AMS Feeders from wearing out, and they will, especially if you use any materials in the AMS that are even slightly abrasive.
• Easier to load filament into the AMS feeders due to the angled design, larger button, and superior grip texture.

What's unique to The SENATE?

• Angled hole for PTFE tube to point it more towards the spool.
• Narrower front bevel to accommodate full spools.
• Larger (wider) button, easier to push.
• Optional and unique add-on grip surface, screws on with a single M3x4 socket-head screw.
• Grip cover can be printed in a different color than the main body for a multicolor look, or in TPU for an even grippier surface. I don't think grippier is a word?

Printing instructions:

1. Load models into Bambu Studio or OrcaSlicer.
2. Click auto-orient and auto-arrange buttons.
3. Duplicate the models so you have a total of 4 of each.
4. Print at 0.16 mm layer height.
5. No supports should be needed.
6. I recommended PETG, ABS, or ASA. I have previously printed AMS buttons in PLA, and they eventually wore out and started slipping off.
7. You can try TPU for the grip cover! I bet that would work nicely?

NOTE: To test fit, I would recommend first just printing one and then decide if you need to modify flow rate.

Installation instructions:

1. You may need to take a razor knife and clean up the inside of the hole for the PTFE tube a little bit, filament tends to sag in here as it's printing depending on the filament and temperatures.
2. If you printed the optional grip covers, you can screw them directly onto each of the main buttons using a M3x4 socket-head screw. You will be making your own threads as you screw them in, so it may be very hard to screw them in depending on the plastic you use. You want to screw these down very snug, so the grip cover doesn't spin around.
3. Optionally, if you do not have the screws, you can superglue the grip covers on and let dry for about 1 hour.
4. Snap each of The SENATE onto your gray-colored AMS feeder buttons. They are specifically designed to be a TIGHT fit, so they stay on. For the easiest installation, you should push the gray button forward, tilt them sideways at an angle to “hook” the underside beveled edge onto one side of the gray AMS feeders, and then snap the other side down and on. It is a bit tricky, but you should get a feel for it. Do not force anything too hard, but you will need to use a little bit of force.
5. Cut four PTFE tubes (4mm OD) to about 20mm in length to stick into each of The SENATE. These are designed to fit the BambuLab tubes snugly and will be a very tight fit, but you should be able to get them in if your extrusion calibration is correct. If you are using another brand PTFE tube, the fit may be more snug or loose. You can try increasing or decreasing flow rate in the slicing program by about 1-3% if your test print does not fit well. TIP: Push them in with a solid, flat object at the top of the tube while holding the tube with your other hand - and remember, they go in at an angle, not straight-in.

FAQ:

Q: Do you need to use the PTFE tubes?
A: No, but it helps prevent wear from abrasive filaments on The SENATE and helps the filament guide through it a little bit more smoothly. You should cut the PTFE tubes about 20mm in length or shorter, any longer and they might touch a full spool and bind up.

Q: What screw size do I need to attach the grip covers?
A: M3x5mm for v1, M3x4mm for v2, these are socket-head metric screws, but you may be able to use other types of screws of similar length. You can also superglue the grip covers on if you wish.

Q: What material should I print these in?
A: For the main body, I recommend a durable filament such as PETG, ABS, ASA, Nylon, PC, etc. You can probably use PLA, but it may wear out quicker. For the grip cover, you can use anything you want, I might even suggest TPU.

Q: It's way too tight and can't get it on, or too loose and falls off.
A: You want it to be very snug. I recommend tilting it and “rocking” it on from the front to the back or side to side (there's a lip under the main object that snaps underneath the gray funnel). If you still can't get it on, you need to decrease your flow rate in the slicing software 3-5%. If it's too loose and falls off, or the PTFE tube easily comes out, you need to re-print and increase your flow rate 3-5%.

Q: Can I print this with a 0.6mm+ nozzle?
A: No you need a 0.4mm nozzle, and a 0.2mm nozzle would be even better if you have one.

Q: How do I get the screws in?
A: The hole for the screw should print slightly smaller than the diameter of the screw thread, you are going to turn the screw in, and it should self-tap into the plastic. It may be a bit hard to do since the screw is very small, but it can be done.

Q: How long does it take to print?
A: It takes about 20 minutes to print one of both the main button and the grip cover, or about 45 minutes for a complete set of 4 SENATE (8 total pieces). It may vary depending on your printing speed settings.

To-Do:

• Create extra versions with tighter and looser holes to fit different PTFE tubes.
• Design a better attaching method for the grip covers, a screw may be a bit ugly for some. Some kind of snap in?
• Move button forward more, some of it is hidden behind AMS front lip. This was accomplished in v2 of the design, but can still be further adjusted.
• Modify design to be an even better fit. It fits snugly, but seems like over time it may pop off or become loose. Need to enhance the attachment lip with some sort of bevel to both make it go on easier and also make the lip wider, so it stays on better.
• Make the button even bigger? It could be made wider for people with sausage fingers, but certainly cannot be made any taller, or the AMS lid will bump into it.
• Export the STLs in the correct printing orientation. Fortunately, the “auto orient” button in Bambu Studio / OrcaSlicer will place them in correct printing orientation automatically and is not a big deal.

Remixing + Improvements

Feel free to contribute. Please provide feedback and suggestions, I am open to further enhancing the design through future versions. Remix if you want, just please pay it forward and share .step file.

Version History

v2 - 2023.06.26

• Made the entire unit shorter, so the button does not hide behind the AMS front lip edge as much.
• Now uses a M3x4mm screw instead of a M3x5mm screw for the grip cover. You can still superglue the grip cover on if you don't have the screw, or not use the grip cover at all.
• Made the entire button slightly smaller to prevent AMS lid from resting on the button.
• Extended the bottom lip to attempt to hold the device onto the AMS feeder funnel better.
• Other small aesthetic changes.

v1 - 2023.06.25 - original upload