Upgrade of the Voxelab Aquila/Ender 3 3D printer to premium class

High precision mechanics

HIWIN linear rails with ceramic:

HIWIN rails on all axes instead of standard V-rollers Ceramic bearings instead of metal balls Elimination of play and runout Smooth operation - the portal moves with one finger Minimal friction and wear Increased service life Result: max_velocity 300 mm/s, max_accel 5000 mm/s²

Dual Z system with auto-synchronization:

Two independent belt-driven stepper motors Z Z_TILT_ADJUST - automatic leveling of the portal before printing Compensation for mechanical skew Each motor is controlled independently via Klipper Smooth operation without jamming Uniform layer height across the entire print area Optimized parameters: max_z_velocity 5 mm/s, max_z_accel 150 mm/s²

Creality Sprite Pro Extrusion System Creality Sprite Pro Direct Drive:

Direct Drive filament feeding instead of Bowden Ceramic heating block - fast and even heating Temperature range: up to 300°C for high-temperature materials Minimum retraction: 0.5-1.0mm (vs 4-6mm on Bowden) Hardened steel nozzles - printing with abrasive materials (carbon, metal filament) Dual gear drive for reliable filament grip Available nozzles: 0.25mm, 0.4mm, 0.6mm with optimized profiles

Filament sensor:

Optical/mechanical sensor at the entrance to the extruder Detection of filament end/absence Automatic print pause on breakage Prevention of loss of hours-long prints Integration with Klipper for smart control

Improved cooling of components:

Additional cooling fan for the model Symmetrical cooling from all sides Improved quality of bridges and overhangs Clear geometry of small details Ability to print PLA at high speeds without deformations

Advanced Sensing BTT Eddy Duo eddy current sensor:

Eddy current principle - measures the distance to metal Positioning accuracy: 0.017mm (Z_TILT result) Temperature compensation (eddy-ng mode) Automatic bed leveling before each print Connection via CAN bus 1000kbps Adaptive bed mesh with automatic print area detection

ADXL345 accelerometer:

Input Shaper - automatic resonance compensation Optimized profile: EI shaper at 36Hz Print speeds up to 300 mm/s with minimal vibrations Improved quality at high speeds Periodic calibration for precise tuning Square corner velocity: 7.0 mm/s thanks to ceramic bearings

Electronics and Control BTT SKR Mini E3 V3.0:

32-bit controller STM32G0B1 processor TMC2209 silent drivers - silent operation USB connection to Raspberry Pi 4 Control of all motors and heaters Optimized limits: 5000 mm/s² acceleration, 300 mm/s speed Backup board: original Creality 4.2.x

BTT EBB36 v1.1 toolhead:

CAN Bus 1000 mkbps - minimum wires to the print head Control of Sprite Pro extruder Monitoring of heater and thermistor Connection of cooling fans Filament sensor via EBB36 Katapult bootloader for convenient firmware updates

BTT Eddy Duo:

Connection via CAN bus 1000kbps Katapult bootloader for convenient firmware updates Integration with the toolhead via CAN Synchronization with EBB36 on the same bus

Klipper firmware:

Raspberry Pi 4 as a host controller Mainsail/Fluidd web interface Remote control and monitoring Advanced features: Pressure Advance, Input Shaper, Z_TILT_ADJUST Simple updates via web interface Optimized Orca Slicer profiles for the current configuration

User Interface Dual Screen Setup - Two screens for maximum convenience: BTT TFT50 V2.0 - Main control interface:

5" capacitive IPS high-resolution touchscreen DSI connection directly to Raspberry Pi (Display Serial Interface) 5-point multitouch - smooth and responsive control Full interface for KlipperScreen/Mainsail Control of all printer functions Configuration of print parameters Calibrations (mesh, Z_TILT, Input Shaper) Real-time webcam viewing File manager for model selection Monitoring of temperatures and statistics Quick access to Klipper macros

BTT KNOMI V2 - Compact status monitor:

2.4" round IPS display with touch control Wireless connection via WiFi Compact placement on the printer frame Quick monitoring of print status Display of hotend and bed temperatures Print progress (percentage, time) Print speed and filament feed Integration with Klipper via Moonraker API Customizable themes Independent operation without wires

Advantages of dual screens:

TFT50: Complete control and configuration at the workstation KNOMI: Quick status check right at the printer Flexibility: Any screen can be used as needed Convenience: No need to approach the computer for monitoring

Thermal Control Aluminum bed 6mm:

Rigid platform without deformations Uniform heat distribution 500W 220V heater through Omron SSR relay Rapid heating to 100°C in 2-3 minutes Flexible magnetic sheet on aluminum bed PEI sheet on spring steel with textured surface Easy removal of parts along with the sheet Compatibility with BTT Eddy Duo Textured surface for perfect first layer adhesion

Sprite Pro ceramic block:

Rapid heating to operating temperature Uniform heat distribution in the nozzle Temperature stability ±1°C Compatibility with high-temperature plastics (PETG, ABS, Nylon, PC)

Automation BTT Relay V1.2:

Automatic shutdown of 220V after 15 minutes of inactivity Control via GPIO23 on Raspberry Pi 4 Energy saving Overheat protection during prolonged inactivity Monitoring through Klipper macros

OctoEverywhere AI monitoring:

Cloud access to the printer from anywhere in the world AI detection of printing defects in real time Automatic stop upon detection of issues Smartphone notifications about printing status Integration with KNOMI for remote monitoring

Dual camera setup:

Two cameras for monitoring from different angles Overall view of the print + close-up of the hotend Timelapse recording of the process Integration with OctoEverywhere for remote monitoring

Aesthetics and quality of execution Custom color scheme:

Black aluminum frame - a strict professional base Red accents - X portal, TFT50 screen, mounting components Pink-purple Sprite Pro - a bright focal element Silver HIWIN rails - a technological appearance of premium components Thoughtful color scheme creates visual harmony

Professional organization:

Clean wire routing - no hanging loops or clutter CAN bus architecture - minimal wiring to the print head Thoughtful placement - each component in its designated spot Symmetry and alignment - attention to detail at all levels Dual Screen system - KNOMI on the portal, TFT50 in the workspace

Additional equipment:

CREALITY Smart Kit - filament dehumidifier with humidity control Dual spool holders - upper for active filament Integrated camera system - two cameras for full coverage Neat wiring - all cables routed through guides

Attention to detail:

No protruding screws or crooked mounts All components are securely fastened Professional level cable management Visually clean and organized system Result: the printer looks like a factory premium system, not a DIY modification

Upgrade Results Achieved Indicators:

Z_TILT accuracy: 0.017mm (professional system level) Maximum speed: 300 mm/s with resonance compensation Maximum acceleration: 5000 mm/s² (HIWIN ceramic + Input Shaper) Square corner velocity: 7.0 mm/s (fast cornering) Printing speed range: 30-300 mm/s depending on the profile Autonomy: full automation of the printing process Reliability: filament sensor + AI monitoring Quality: improved cooling + Direct Drive Versatility: printing of any materials up to 300°C Print area: 228×219 mm (optimized for actual nozzle boundaries)

Comparison with the original Voxelab Aquila: Parameter Original Modified Rails V-rollers HIWIN with ceramics Z-axis One motor Dual Z belt-driven + Z_TILT Extruder Bowden Sprite Pro Direct Drive Nozzles 0.4mm only 0.25/0.4/0.6mm with profiles Bed sensor Manual leveling BTT Eddy Duo (0.017mm) Controller Creality 4.2.x SKR Mini E3 V3.0 Toolhead Standard EBB36 v1.1 (CAN 1000kbps) Firmware Marlin Klipper Input Shaper No ADXL345 (EI 36Hz) Filament sensor No Optical sensor Part cooling One fan Dual fan system Max. temperature 240°C 300°C Monitoring No 2 cameras + AI Screen LCD 2004 TFT50 V2.0 (5" DSI) + KNOMI V2 Max velocity ~80-100 mm/s 300 mm/s Max accel ~500-1000 mm/s² 10000 mm/s² Square corner ~5 mm/s 7.0 mm/s Print area 220×220 mm 228×219 mm Functional improvements:

Creality Sprite Pro - fast heating, precise extruder, minimal retraction (0.8mm) Filament sensor - protection against breakage and depletion of plastic Improved cooling - quality bridges, overhangs, fine details Hardened steel nozzles - carbon, copper filament, wood composites Ceramic block - stable temperature for any materials PEI textured sheet - excellent adhesion without glue Dual Screen System - TFT50 (control) + KNOMI V2 (monitoring) HIWIN ceramics - capability for extreme speeds and accelerations Extended printing area - utilization of 99.8% of the table surface

Optimized profiles for Orca Slicer:

0.25mm nozzle: 0.08mm ULTRA DETAIL, 0.12mm HIGH DETAIL, 0.15mm SPEED, 0.20mm ULTRA SPEED 0.4mm nozzle: 0.12mm DETAIL, 0.20mm SPEED, 0.28mm ULTRA SPEED (universal) 0.6mm nozzle: 0.20mm QUALITY, 0.30mm FAST, 0.36mm ULTRA FAST All profiles are optimized for 5000 mm/s² acceleration and 300 mm/s speed.

Practical application:

Printing functional parts from engineering plastics Production of small series with high repeatability Hours-long prints with automatic control Printing with abrasive and composite materials Remote monitoring and control via the internet High-speed prototype printing (up to 300 mm/s) Detailed printing of miniatures (0.25mm nozzle, 0.08mm layer)

Upgrade cost: ~$790-900

HIWIN rails: $150-200 Sprite Pro: $80-100 SKR Mini E3 V3.0: $40-50 EBB36 v1.1: $40-50 Eddy Duo: $70-80 TFT50 V2.0: $40-50 KNOMI V2: $35-45 Filament sensor: $10-15 Additional fan: $5-10 BTT Relay V1.2: $20-25 Cameras (2 pcs): $40-60 PEI sheet: $20-30 Raspberry Pi 4: $50-70 Miscellaneous (wires, fasteners, etc.): $50-100

Final level: Comparable to premium printers such as Prusa MK4 ($1200), Creality K1 Max ($800), Bambu Lab P1S ($700) Advantage:

Full control over the system Understanding of each component Possibility for further upgrades Excellent mechanical characteristics (HIWIN ceramics) Flexibility in configuration for any tasks

Transforming the budget printer Voxelab Aquila for $200 into a professional system with an accuracy of 0.017mm, acceleration of 5000 mm/s², speed of up to 300 mm/s, process automation, and the capability to print with various materials.

Specifications Printer

Base: Voxelab Aquila (extensively modified) Frame: Original aluminum, reinforced

Mechanics

Rails: HIWIN with ceramic bearings (all axes) Z-system: Dual motor belt-driven + Z_TILT_ADJUST Z_TILT accuracy: 0.017mm Max velocity: 300 mm/s Max acceleration: 5000 mm/s² Square corner velocity: 7.0 mm/s Z velocity: 5 mm/s Z acceleration: 150 mm/s²

Extrusion

Extruder: Creality Sprite Pro Direct Drive Heating Block: Ceramic, up to 300°C Nozzles: Hardened steel 0.25mm, 0.4mm, 0.6mm Retraction: 0.8mm (Direct Drive) Filament Sensor: Optical/mechanical sensor Model Cooling: Dual fan system

Electronics

Motherboard: BTT SKR Mini E3 V3.0 (STM32G0B1) Drivers: TMC2209 silent Toolhead: BTT EBB36 v1.1 (CAN 1000kbps) Bed Sensor: BTT Eddy Duo (eddy current, 0.017mm) CAN Bus: 1000kbps (EBB36 + Eddy Duo) Accelerometer: ADXL345 (Input Shaper EI 36Hz) Automation: BTT Relay V1.2 (GPIO23 Pi4) Main Screen: BTT TFT50 V2.0 (5" DSI capacitive, 5-point touch) Status Monitor: BTT KNOMI V2 (2.4" round WiFi) Backup Board: Creality 4.2.x (original)

Thermal control

Table: 6mm aluminum Heater: 500W 220V via Omron G3NB-225B SSR Surface: Magnetic sheet + PEI on spring steel (textured) Heating to 100°C: 2-3 minutes

Firmware and control

Firmware: Klipper Host: Raspberry Pi 4 Interface: Mainsail/Fluidd web UI Monitoring: OctoEverywhere AI + 2 cameras Bootloader: Katapult (EBB36, Eddy Duo)

Operating characteristics

Print area: 228×219×250mm (extended) Usage area: 99.8% of physical boundaries Speed range: 30-300 mm/s (with Input Shaper) Resonance: 36Hz compensation (EI shaper) Materials: PLA, PETG, ABS, ASA, Nylon, PC, TPU, composites, abrasive Hotend temperature: up to 300°C Bed temperature: up to 100°C

Orca Slicer Profiles

0.25mm: ULTRA DETAIL (0.08mm), HIGH DETAIL (0.12mm), SPEED (0.15mm), ULTRA SPEED (0.20mm) 0.4mm: DETAIL (0.12mm), SPEED (0.20mm), ULTRA SPEED (0.28mm) 0.6mm: QUALITY (0.20mm), FAST (0.30mm), ULTRA FAST (0.36mm) All profiles: optimized for 5000 mm/s² and 300 mm/s

Cost

Original printer: ~$200 Upgrade: ~$790-900 Total: ~$990-1100 Level: Premium ($1000+ class)