40mm cooling fan duct for Smart Effector - thoughts?

[RGN01]

@dc42:

Noctua makes 5V fans too, so another option is to use 5V fans throughout.

My Duet cooling fans are 12V so it is easy to do - once I get the case opened (and that is nothing to do with the Duet, it is all my own doing!)

Richard

[RGN01]

Here is my 'final' (is anything ever final in 3D printing? ) design for the Volcano. Still to be tested on the printer.

Perspective is misleading in that last photo - the Noctua fan inner edge is parallel with the edge of the board.

I will add a printed retaining mount to the blower fan and then a set of aluminium tusks for layer cooling.

The only place this mount touches the PCB is on the 4 11mm nut retaining tabs. It barely touches the heatsink so I'm not expecting it to degrade probing.

Richard

[RGN01]

Now fully loaded and waiting for me to convert the fan supply on the Duet to 12V

I must only still add the tusks to the fan - a 6mm aluminium tube either side should be easily achievable, I think.

Should be interesting to test it.

Richard

[c310]

as an option i have created 40 mm fan bracket to replace original one (30*30)
it fits with original model cooling fan duct.

https://www.thingiverse.com/thing:2822678

[Nuvag]

Nice!
I'm just printing one and found two minor problems:

• Simplify3D hangs up if using more than 2 perimeters (tried multiple times)
• The text on the side is too small to be printed, there are only artefacts visible

[Nuvag]

Just mounted it and fits perfectly, thx c310!
Additionally it doesn't interfere with the touch sensor like the 30mm fan did, so no need to turn the fan of during autocalibrating

I'm slightly worried it could slip down, would be nice if it had a hinge above the top most full cooling fin of the heatsink and prevents it from slipping down.

[RGN01]

My development and testing is delayed as I'm waiting for a new Nimble for the Volcano. I'll report back once I receive that and get it mounted.

Richard

[Vigilant]

@RGN01:

Now fully loaded and waiting for me to convert the fan supply on the Duet to 12V

https://i.imgur.com/fsleZj7l.jpg

https://i.imgur.com/cLcZwSfl.jpg

https://i.imgur.com/svgvfvgl.jpg

https://i.imgur.com/E5TOV7Sl.jpg

https://i.imgur.com/uBTwwtyl.jpg

I must only still add the tusks to the fan - a 6mm aluminium tube either side should be easily achievable, I think.

Should be interesting to test it.

Richard

I'm using a 40mm fan duct adapter , and I noticed that the nimble mount nut below is blocking it from being mounted properly. How are you mounting the nimble?, are you using a nut? Do you have the STL for this ?

[RGN01]

My Nimble is mounted using one of the adapters from Shapeways, 3mm cap screws and 1/2 nuts below the board. My design incorporates a recess for the one bolt and nut.

Yes, I have the STL (it is my design) but it is untested at this time as I need to wait for another Nimble and have to convert the fan voltage to 12V from 24V. I hope to do that this weekend.

I'm happy to put the STL on Thingiverse on the understanding it is still WIP. Which one are you interested in? The one for the v6, or the Volcano one with layer fan?

Richard

[RGN01]

Update:

I have now finalised the design for the duct and it works well on both my Smart Effectors using 40 x 10mm Noctua fans.

I decided to go with the BerdAir type approach as the Smart Effector became too cluttered with the layer fans on it. I'm still working on the piping and mounts for these.

See the 40mm fan duct here https://www.thingiverse.com/thing:2844881

Richard

[Mysta]

@RGN01:

Update:

I have now finalised the design for the duct and it works well on both my Smart Effectors using 40 x 10mm Noctua fans.

I decided to go with the BerdAir type approach as the Smart Effector became too cluttered with the layer fans on it. I'm still working on the piping and mounts for these.

See the 40mm fan duct here https://www.thingiverse.com/thing:2844881

Richard

I commented on the thingiverse post as well but wanted to mention here I printed the berd adapter and the 40*20 fan duct, everything went well(though leveling them was a pain) used supports. The cylinder around the heatsink was a little brittle - slightly broke it when I was removing supports but could be my PETG print settings.

Here was my orientation(tested the other adapter too) https://i.imgur.com/mXVaazo.png

[RGN01]

Thanks for reporting back. Try printing with the feet on the bed - mine prints perfectly like that with support only on the bed.

I've also uploaded a STL file for the combination of the duct and BerdAir tube mount.

Richard

[RGN01]

I've uploaded an improved version for the BerdAir type cooling. It only needs support on the bed - I've included sacrificial support for the rest of it.

Mine prints perfectly in PETG with only minimal support plastic to remove.

Richard

[benkay]

Looks great. With the new easy-print version for berd-air….is this file universal for standard v6 and volcano?

[benkay]

Looks great. With the new easy-print version for berd-air….is this file universal for standard v6 and volcano?

[RGN01]

Yes, I use the same for both.

Richard

[Hergonoway]

@rgn01

Hi love your design, could you share the stp/step files ? at least for the "Duct_-_no_accessories_v1.00" part ?

I'm struggling right now in Fusion 360 with the stl, there more than 45k meshes

[RGN01]

@hergonoway Unfortunately the CAD package I use does not support STP files so I can't do that.

Richard

[BenDiesel]

That fan I a cool idea. I used this one for a 40mm noctua on mine
https://www.thingiverse.com/thing:2844881

[Hergonoway]

@rgn01 I was sad at first because working with this amount of mesh kill my Fusion360... and working from mesh is really not my cup of tea... but your idea of using a 40mm fan made its way into my mind I've ended up designing my version from scratch in order to handle 3mm holes for fan with hexa nut lock and working as a shield with berdair support (for original tube size but also 1/8" tube size), so thank you !!

[Chipsa82]

@hergonoway that is pretty much the ultimate mount for the effector ;)) would you mind sharing the model? thanks!

[Chipsa82]

@rgn01 Cool! is that a 40/20 blower fan?

[RGN01]

@hergonoway that looks very good. Sorry I couldn't help directly and save you the trouble of redesigning it!

[RGN01]

@chipsa82 on the early photos with a blower, yes. The Noctua on the later version is a 40 x 10. I have shared my version on Thingiverse https://www.thingiverse.com/thing:2844881

[Hergonoway]

@chipsa82 I'll post it on thingiverse in few days, need to rework some clearance for that damn screw under the fan duct

First prototype print works like a charm