Orbiter v3.5 summary
Orbiter v3.5 represents the next step in the evolution of the proven Orbiter v3.0, with several improvements for enhanced performance and reliability.
The main mission of this design is the continuous refinement of the Orbiter v3.0 architecture, with a focus on reduced noise, increased robustness, improved tolerances, and expanded hotend compatibility.
Our favorite manufacturer of the Orbiter v3.5, of course, is LDO Motors!
Features
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.
Highlights of the new Orbiter v3.5 features:
üDesigned to be compatible with both our hotend design and
the E3D Revo ecosystem
üHeat-break performance optimized with finite elements
analysis for extreme temperature gradient design to ensure clog-free printing
experience;
üUnique tensioning mechanism with elastic, predefined tension
levels
üFrameless recessed 24V fan to reduce the extruder weight and
outside dimension
üLarge RNC-coated dual-drive gears with planetary gear
reduction, similar to orbiter v2.0
üNew knurled precision main shaft design to reduce gear
eccentricity
üFull aluminum housing with Delrin plastic gears for low
noise and long lifetime
üThe smart feature—integrated electronics
üEasy removal system of the secondary drive gear for easy
cleaning and maintenance
üDouble filament exit guide system for best TPU printing
performance
üPure plated copper heat-block with 72W ceramic heater
and TFN
nozzle for highest possible weight-to-flow ratio
Orbiter v3.5 specifications summary:
üDrive type: 12mm dual drive extrusion system
üWeight: 175g including standard hotend
üNominal steps / mm: 690 (16x micro stepping) /
1380 (32x micro stepping)
üRotation distance: 4.69
üExtrusion force: 6.5 kg+
üGear ratio: 7.5:1
üMax stepper current: 0.85A RMS (1.2A peak), derating over
50°C ambient temperature.
üMin stepper current: 0.55A RMS (0.75A peak) for operation
up to 70°C ambient temperature
üHeater temperature sensor type: ATC Semitec
104NT-4-R025H42G
üExtruder fan: 24V frameless fan with speed signal
üMaximum operating temperature: 90°C (with motor current
de-rating down to 0.55A RMS)
üFilament sensing
üFilament unload
üHotend lit
üFilament input lit – RGB LED WS2812B type
üExtruder temperature sensor: 100K NTC Generic 3950
üSmart features supply: 3.3V or 5V
Firmware configuration remains mostly unchanged from Orbiter v3.0. Please check the Orbiter v3.0 webpage for detailed configuration information.
The only difference is the chain_count setting of the internal SO3RGB definition, which must be changed from 1 to 2.
The Orbiter v3.5 equipped with the LDO hotend comes by default with our high-flow TFN nozzle.
What's improved compared to v3.0
üFront heatsink redesigned for reduced fan turbulence
noise
üThe Filament sensor upgraded for more reliable detection
and fewer false runouts
üBetter control of filament path positioning thanks to
fewer stacked parts
üUpdated internal RGB LED chain (two LEDs)
üSmall mechanical refinements (tolerances, pivot hardware,
mounting geometry)
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
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.
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.