140mm USB-powered desk fan

thingiverse

I'm on the hunt for a desk fan that won't break the bank, but every option I've found is overpriced, mediocre, and doesn't last long. I'm talking about fans with brushed motors that seem to have a lifespan of only two years. They're also not exactly repairable, which is a major turn-off for me. So, I decided to take matters into my own hands. I headed to eBay and picked up some essential components: a 140mm brushless computer fan ($3.60), a USB DC 5V to 12V step-up module with a 2.1x5.5mm plug ($1.65), a male/female 2.1x5.5 jack/plug connector ($0.75), and some #6-32 x 1.5" coarse threaded Philips head screws and nuts from my local hardware store (just over $1). I only needed four of the six, but it was worth it to have a spare. The total cost? Under $8 in materials. Not bad for a DIY project! Next up was designing the frame and stand that would hold the fan and allow it to tilt. I wanted something simple, easy to assemble and disassemble, and easy to print. I came up with a design that prints well without supports, but if you want to add some extra stability to your corner brackets, go for it. Assembly is pretty straightforward – no glue needed! The corner brackets hold the side panels in place with minimal wiggle room, and tolerances are loose enough to accommodate a wide range of printers. I've included two sizes of nuts: one scaled to 106% of the thread size, and another to 107%. Depending on your printer's tolerances, you might need to choose one or scale it yourself. The end result is a fan that moves some air, but not as much as commercial units. However, I love the fact that I can plug this into any USB socket (even a portable power supply!) and swap out the fan if it ever burns out. If you want to support me and get great filament at the same time, be sure to visit Proto-Pasta using my affiliate link and grab some excellent HTPLA! Disclaimer: There's no fan guard, so please exercise common sense when handling this project. If you have kids, keep it out of their reach or print a fan guard – Thingiverse has plenty of options. If you do decide to make this: Happy printing! Let me know if you have any questions in the comments and I'll do my best to answer promptly. Print Settings: Printer: BobsCNC RP9 v2 Rafts: Doesn't Matter Supports: Doesn't Matter Resolution: 0.2 mm Infill: 30% How I Designed This: I used Autodesk 123D Design, along with digital calipers and mental geometry to get the design just right. It was a fun project that shows off the power of free programs like Autodesk's 123D Design.