6 blade 40cm fan_ one piece blade

thingiverse

In my initial trial, I printed the blade vertically using 0.4mm layer height, 2 perimeters, and 10% infill (honeycomb 30°) with Slicer 1.0.0RC2 software. I added 50 solid layers for a sturdier base foot. Printing in a vertical position made the process faster, but using a cooling fan was necessary due to PLA's sensitivity to speed and cooling. To address sharp trailing edge difficulties, I used a file and water-resistant sandpaper, and paint or filler might be needed for perfection. The spinner STL part was also updated to minimize faults. For future attempts with 645mm diameter blades and parts, scaling 1.612 gives a blade height of 285mm and a propeller diameter of about 645mm. A scale of 80 solid layers on the bottom might be suitable for size 645 prints. Slic3r 1.0.0RC2 allows users to set solid layer numbers for selected parts, making it possible to differentiate solid layer heights in various parts. Scaling does not change the angle of attack, which may affect RPM efficiency. The blade's root cord length and tip design could be further optimized, as the design program used for the propeller appeared limited and basic. Exploring other efficient and quiet fan designs would be beneficial.