3FPD-Rep2X Cooling Duct-Rev2

thingiverse

This cooling duct is under development for Makerbot Replicator 2X Dual-Head 3D Printer to enhance print quality with before and after pictures showcasing its effectiveness. However, the fan must be used along with it, and users should not leave it unattended or use it at their own risk. The design is still a work in progress (23Oct13), but Rev3 has been added for higher flow versions (25Nov13). The purpose of this duct is to create an air blanket across the print head/part, which helps produce better quality finishes on parts with insufficient cooling cycle time. This duct fits the carriage with a 40mm x 40mm x 10mm fan, clearance of approximately 1mm from the surface being printed, and is designed to work with speed control for precise airflow management. It has been optimized for minimal negative impact on part adhesion while maximizing flow to the extruded finish for superior part quality. The duct will also direct cooling air directly to the extruding chambers' heat sinks to prevent filament softening during long prints. This is an ongoing development, and future revisions may include a cooling tube to funnel air directly to the extruder chamber for both heads (Rev2). Instructions: This duct prints without supports and should be mounted in the same orientation as it will be used with the 3F symbol facing the build platform. It can be printed at 100% or 100.7% to account for shrinkage. The OEM fan guards must be removed, and a 1.6mm spacer might be required for outer lower OEM screws. Four metric nuts (3mm) and screws (3mm x 10mm) are needed for mounting the fan. The duct can be installed by placing nuts into nut ports, removing long inner screws, clipping tabs under the plastic carriage front lip, and reassembling with OEM screws. Finally, use a 40mm fan to mount it so that it blows air into the duct, and power the fan using a separate switched power supply, USB cable, or find a lead on the Makerbot itself. Suggestions for improvements are always welcome.