Bearbooster - Pressure Booster for Hotend Cooling

thingiverse

This concept builds upon a "radial flow compressor." Several YouTube videos showcase impressive improvements in static pressure using PC fans. These videos were posted by the user "SgaboLab," so take a look to grasp what this project aims to achieve. https://www.youtube.com/watch?v=bsOOzg9TCa8 https://www.youtube.com/watch?v=rDq4KSlZcTo https://www.youtube.com/watch?v=0TzJNzlkrOU Hey, you're back now! That was pretty cool, right? I've heard static pressure is superior for cooling heatsinks over CFM. This fact has been well-documented, so I'll consider it. Many enthusiasts have upgraded the stock Noctua fan to a more powerful Sunon fan with great results. So, why not design something to enhance pressure over the heatsink using this method? Before we proceed, keep in mind that we tested this mod with the weak Noctua fan and saw no improvement. I recommend against trying this mod with the Noctua; instead, use a more powerful Sunon fan. The idea is to redirect extra airflow moving outward in a more useful manner. I don't believe the Noctua creates enough of this "wasted" airflow to be useful. To evaluate the effectiveness of this mod, we used a script published on the Bear Git repo: https://tinyurl.com/y8nt98d7 This test method heats the hotend to 280 degrees for an extended period, then measures how quickly it cools using the heatsink/cooling setup. If this translates into better prints, I'm not sure; maybe it doesn't matter. However, there is evidence that this at least improves that measurement. Here are results using this part and the latest 0.7.0 Bear cover: $ python ../parse_hotend_cooling_log.py 023/hotend_cooling_v29no_vertigo_02.log t:280.8 b:50.0 t:220.9 b:50.0 t:174.1 b:50.2 t:139.2 b:50.0 t:113.2 b:50.0 t:93.1 b:50.4 t:77.4 b:49.8 t:65.4 b:50.1 t:56.0 b:49.9 t:49.2 b:50.2 $ python ../parse_hotend_cooling_log.py 023/hotend_cooling_v29no_01.log t:278.9 b:51.4 t:226.7 b:51.2 t:183.6 b:51.9 t:150.3 b:50.8 t:125.0 b:50.2 t:105.1 b:50.0 t:89.3 b:50.0 t:76.8 b:50.7 t:66.6 b:50.0 t:58.6 b:49.9 Results show a ~1 min improvement in cooldown time from 280C to 50C, and a 12C degree difference in temperature after 5 mins of cooling. There are two versions of this part: one works with the 0.6.0 version of the Bear extruder, and the other works with the development version 0.7.0. To print this part, use at least .1mm layer heights or less, and .45mm extrusion widths are recommended. PLA should be fine; however, PETG may be harder to print.