BareBone Fan System

thingiverse

There is a world where fan systems reign supreme. I embarked on a quest to find the perfect blend of silence and efficiency, but it seemed like an unattainable goal at first. However, if you're searching for a strong airflow and a top-notch cooling fan, then this project might not be your cup of tea. You'll likely need a radial fan system that boasts 33db-45db noise levels. On the other hand, if you're on the hunt for a virtually silent and adequately cool fan system, then you've come to the right place. This design utilizes three 40mm axial fans, each producing an astonishingly low 14db of noise. You can literally put your ear inches from them without even noticing. The entire structure is remarkably lightweight and minimalist (barebone), making it easy to print without any special settings. Feel free to adjust the infill percentage between 20-50% to suit your taste. What's more, you won't need any supports at all. The Central Mount makes use of the stock X carriage but can easily be adapted to modified ones. It features six holes, but you can opt for just four if needed. The nearest set of holes maintains the same distance as the stock X carriage, while the farther set provides more resistance and reduced vibration - simply drill out those two additional holes in the X carriage. The Front and Rear pieces are designed to hold the upper part of an E3D V6 head, which is a modification from another project you can find here: https://www.thingiverse.com/thing:2333471. I chose to use a conical duct for enhanced efficiency due to axial fans' low-pressure characteristics. In front of the Central Mount lies the Central Duct, cleverly designed to blow air directly at the heatsink without hitting the heatblock. Simply screw it in with the correct orientation. The Left and Right Ducts are optimized to maximize airflow from a cone-shaped duct in front of an axial fan. As you may know, placing a cone or converging duct right after an axial fan would result in poor efficiency due to its low pressure output. Rapid changes in direction and small passages should be avoided, as they create vortices that disrupt airflow. To resolve this issue, I designed four independent cones within the ducts. An external ogive ensures linear airflow over the piece. For optimal results, consider using a 40x40x20 fan to achieve consistent air flow. Be cautious not to hit any components like the extruder or mainboard if they're placed on the Z axis. Lastly, the Joint allows for adjustable and trimmable airflow towards the piece instead of the heatblock. To ensure a snug fit for 3mm screws and nuts, print holes with a slight tightness, allowing you to drill them out slightly. When placing nuts inside fittings, use a long screw, warm it up with a torch (I used my kitchen cooker), and then force it into the hexagonal hole. If you'd like to move your sensor behind the X stock carriage, install this bracket: https://www.thingiverse.com/thing:2959853. A picture of a bridge test showcases 18cm long prints without any issues using these settings: PLA+, 65°C/205°C, 0.2mm layer, 50mm/s I hope you enjoy this FanSystem.