Orbiter v3.5 represents the next step in the evolution of the proven Orbiter v3.0, with several improvements for enhanced performance and reliability.
✓ Reduced False runout detections
✓ Better control of filament path tolerance
✓ More precise extrusion—knurled main shaft
✓ New TFN nozzle, improved maximum flow-rate and layer precision
Features
Orbiter v3.5 specifications summary:
✓ Weight: 175g including standard hotend
✓ Nominal steps / mm: 690 (16x microstepping) / 1380 (32x microstepping)
✓ Rotation distance: 4.69
✓ Extrusion force: 6.5 kg+
✓ Maximum operating temperature: 70°C (0.55A RMS stepper current)
✓ Filament sensing and automatic unload
The new Orbiter v3.5 is based on the well-known Orbiter v3.0, with several refinements that further enhance its extrusion performance. The technical characteristics of Orbiter v3.5 remain largely the same as those of Orbiter v3.0; please refer to the Orbiter v3.0 webpage for detailed specifications.
Orbiter v3.5 detailed changes description
Front heatsink
The main change in Orbiter v3.5 is the redesigned front heatsink. The new fin shape reduces air turbulence and helps eliminate the annoying ‘mosquito’ fan noise (~-10dB).
Orbiter v3.0 front heatsink
Orbiter v3.5 front heatsink combo
The front heatsink is designed to be compatible with both our hotend design and the E3D Revo ecosystem.
Orbiter v3.5 LDO Hotend + TFN nozzle
Orbiter v3.5 + E3D Revo ecosystem
Note: The E3D Revo hotend is 4 mm longer than the LDO hotend!
The heatsink and hub housing have been widened by 0.5 mm. This ensures that the left-side extruder mounting surface sits further outward than the stepper motor body, improving mounting alignment. As a result, the Orbiter v3.5 is 0.5 mm wider than the previous v3.0.
The front heatsink and filament guide are now combined into a single part, improving tolerance control of the filament path and its distance to the filament sensor. This also reduces the number of parts that need to be aligned, making the design less sensitive to manufacturing tolerances.
The input ring geometry has also been redesigned to accept a small PTFE coupler, ensuring the PTFE tube is mechanically retained rather than relying only on friction.
Orbiter v3.0 two-part design
Orbiter v3.5 combined design
As shown above, the filament sensor has been redesigned using the same sensor switch as the Orbiter v2.0 smart filament sensor. This results in more reliable filament detection, reduced friction in the upper section of the extruder, and more reliable runout detection without false events.
The new sensor board features two RGB LEDs instead of one, so the Klipper RGB LED configuration must be updated to define two LEDs in the chain_count.
Drive gear tension lever
The retaining screw for the secondary drive gear tension lever has been changed from a standard M3 screw to a custom M3 shoulder bolt. This allows the tension lever to pivot on a smooth surface rather than on the M3 threads, as was the case with Orbiter v3.0.
Knurled spider-shaft design
Another change is a new knurled spider-shaft design. Compared to the previous precision shaft (octagon-shaped), the knurled version is easier to manufacture and allows the drive gear to be press-fitted with better alignment. This improved centering leads to more stable extrusion and smoother print quality, reducing visible diagonal artifacts.