LDO Smart Orbiter 3.5
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.
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:
- Designed to be compatible with both our hotend design and the E3D Revo ecosystem
- Heat-break performance optimized with finite elements analysis for extreme temperature gradient design to ensure clog-free printing experience;
- Unique tensioning mechanism with elastic, predefined tension levels
- Frameless recessed 24V fan to reduce the extruder weight and outside dimension
- Large RNC-coated dual-drive gears with planetary gear reduction, similar to orbiter v2.0
- New knurled precision main shaft design to reduce gear eccentricity
- Full aluminium housing with Delrin plastic gears for low noise and long lifetime
- The smart feature—integrated electronics
- Easy removal system of the secondary drive gear for easy cleaning and maintenance
- Double filament exit guide system for best TPU printing performance
- Pure plated copper heat-block with 72W ceramic heater and TFN nozzle for highest possible weight-to-flow ratio
Orbiter v3.5 specifications summary:
- Drive type: 12mm dual drive extrusion system
- Weight: 175g including standard hotend
- Nominal steps / mm: 690 (16x micro stepping) / 1380 (32x micro stepping)
- Rotation distance: 4.69
- Extrusion force: 6.5 kg+
- Gear ratio: 7.5:1
- Max stepper current: 0.85A RMS (1.2A peak), derating over 50°C ambient temperature.
- Min stepper current: 0.55A RMS (0.75A peak) for operation up to 70°C ambient temperature
- Heater temperature sensor type: ATC Semitec 104NT-4-R025H42G
- Extruder fan: 24V frameless fan with speed signal
- Maximum operating temperature: 90°C (with motor current de-rating down to 0.55A RMS)
- Filament sensing
- Filament unload
- Hotend lit
- Filament input lit – RGB LED WS2812B type
- Extruder temperature sensor: 100K NTC Generic 3950
- Smart 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
- Front heatsink redesigned for reduced fan turbulence noise
- The Filament sensor upgraded for more reliable detection and fewer false runouts
- Better control of filament path positioning thanks to fewer stacked parts
- Updated internal RGB LED chain (two LEDs)
- Small 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 centring leads to more stable extrusion and smoother print quality, reducing visible diagonal artifacts.
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