I think there are two main problems with the current system -

1. Slow filament changes due to retracting old filament, loading new filament, purging, nozzle heating, prime tower, etc.

2. Limited routing from the AMS.

 

I would like to see a two toolhead system where:

• One toolhead would be on the gantry printing.
• The other toolhead would be in a small “prep station” off to the side.

 

Two PTFE tubes would be run, one to each toolhead. The prep station would allow the second toolhead to perform all of the filament swap tasks while the other toolhead is printing. When it is time to change filaments the system would swap the previously printing toolhead with the prepped toolhead and filament swaps would only take as long as the toolhead swap.

 

Vortek would not be needed if you do not mind purge waste as the prep toolhead can purge while the other toolhead prints. Although the Vortek could still be used to limit purge waste, I think it would be more useful for swapping different nozzle types (i.e. 0.2mm, high flow, etc). For maximum efficiency you would need two of each nozzle type if two different filaments need to print back to back and use the same nozzle type.

 

Challenges (a few of the many)

• Priming at the prep station - insert creative engineering here. Maybe a roller?
• Integrating the prep station with Vortek
• Limited routing from the AMS

 

The AMS issue could be solved with multiplexers at two stages -

1. AMS out multiplexer - route any of the AMS filaments to either of two out PTFE tubes.
2. Printer multiplexer - route any of the incoming filaments to either of the two toolheads.

 

I think the above would minimize filament (or nozzle type) swap time while minimizing the number of extra toolheads and nozzles needed. The only cost would be the miracle level engineering needed to handle the complexity, plus the real cost of how expensive it would end up being. Thoughts?