Combined Ender3 Direct Drive, Fan duct, and BL Touch mount

thingiverse

This is a remix of several components combined into one solution for the hotend on Creality Ender 3 and similar models. It offers Direct Drive, a BL Touch Mount with an enlarged area to eliminate springs, and a built-in fan duct system all in one piece. The part requires supports due to its complexity, but the outer channel has small holes for zip ties, allowing for easy cable management at the hotend. I printed it using 3DFuel's Daffodill Yellow Standard PLA. Edit 1: I decided to print this item in a vertical orientation, with the base of the cooling duct on the build plate. I used Conical supports everywhere and a support blocker through the cooling duct part. Updates and pictures will be added as progress is made... Edit 2: It's been printed and installed. Pictures show how wiring lays in my setup. Notes include printing with the face of the front fan grill on the bed, using a support block in the part cooling duct, and creating a hole for wire in the BL Touch mount. I used Conical supports with CHEP's Cura 4.5 Beta profile at .2mm layer height, along with 5% infill in a grid pattern. The front fan model was chosen for a 50mm fan, so the stock fan is a loose fit. There are currently no holes for fan mounting, so I simply used CA glue on the bottom ledge and centered the fan on it. While not super secure, it won't move around. I'll work on adding fan mount holes. The part cooling fan holes are perfectly suited for the stock screws, but be sure to avoid over-tightening as there isn't much plastic available for threads. Wait until all parts are installed and tightened down before zip-tying cables in, allowing for wiggle room when working with fiddly bits like the BL Touch. At least use the top two ties to prevent excessive movement on cables at the E-Motor. DO NOT PRINT THIS VERSION! I'm currently working on Version 2 due to a flaw that will make the finished part flimsy and useless upon completion. A redesign is underway to eliminate this issue and reduce the need for supports. Version 2 has been posted, incorporating changes to minimize supports and strengthen a weak point. Print with four walls and 5-10% infill. Remember to use a support blocker in the cooling duct.