New Heater Block Concept - Toolhead

After testing the current heatblock design, one thing that stands out is that the temperature isn't consistent in the cross section and the thermistor lags behind a while. This isn't ideal and can cause degradation in the filament, and print quality issues in general.

I've simulated a different design with the thermistor at 90° relative to the heater, at the same distance from it as the meltzone. This should allow for a more responsive and accurate temperature control, and the extra material on the rear should let the back lose less heat making the temperature gradient less severe.

Both simulations are set with the meltzone with a 290° average temperature, with no insulation melting abs at 50mm^3/s in a 80° chamber, with a fan blowing on them:

Old heatblock sim:

• Min/Max meltzone temp: 262°/309°
• Min/Max heatblock temp: 262°/342°
• Power: 96W
• Thermistor reading: 287°

New 90° heatblock sim:

• Min/Max meltzone temp: 265°/308°
• Min/Max heatblock temp: 265°/340°
• Power: 95.8W
• Thermistor reading: 295°

There are improvements, and the temperature control benefits are high enough to warrant further testing, so I'll optimize this design for future tests in the real world. Other interesting improvements are also being considered, such as different heater configurations, and a following post will expand on those.