Using 2x CAT6 cable for 24 V hotend I'm looking to replace the troublesome ribbon cable of my Duplicator 6 with a 2xCAT6 arrangement for all things extruder.


Are 4 26AWG wires (2 sets of 2 twisted pairs) enough copper for 50W heater at 24 volts?
Are 2 26AWG wires (1 set of 2 twisted pair) enough copper for the ground connection of the heater?
Can I consolidate ground connections of the low power fans/sensors to free up more wires?
Is it okay if I have some pins be 24 volt like for the heater and others be 12 volt for the fans?
Should I get a lower gauge CAT6 cable like 24 AWG? 23 AWG seems to exist too.
Do not consolidate ground wires, use as many as the positive ones. In fact, use one wire of each twist for ground and one for the related positive, so that they balance each other.

Mixing voltages is fine, the CAT 6 cable will hold 24 V fine.

Concerning the number of wires, you should check the allowed current per wire and calculate the required number of wires.

Each pair can carry 0.36 A. 50 W is 2 A, you need 6 pairs for the heater.

You get two spare pairs, which can carry in total 0.7 A at the voltage you prefer. You could use two for the thermocouple and two for the fan, or two different fans.