Cooling Fan/Shroud with 5cm Blower and Sensor for Wanhao D6/Ultimate

thingiverse

Finally as much cooling air flow as you need thanks to the EBM-PAPST RLF35-8/14N blower. Version 11 M12 comes with stronger attachments on the left side, allowing for more efficient airflow. This version has three larger nozzles and a bigger duct volume that extends to the back, providing better cooling performance. To optimize airflow and distance between the heatblock and nozzles, turn the heat block by about 25 degrees as shown. Thanks to Reflector for exploring the space behind the print head assembly; I was cautious not to impede on the print area since every mm counts. Version 6 and 7 have four nozzles, but Version 7 has areas removed for better airflow and a more exposed cooling block. Otherwise, it's the same as Version 6. I used the 4-nozzle version for months without issues, making it a safe bet. Version 7 M12 5015 may fit other 5cm blowers, although you might need to shorten the funnel to get it to fit in the available space. This shroud is designed to be printed from the bottom up with minimal support across the blower entry, left fixtures, and right attachment sites. The nozzles print fine without support for the 4-nozzle version but require support for the three-nozzle version. This shroud won't extend beyond the printer dimensions or limit the print area. You'll need 3x 20mm M3 screws (the original ones), 2x 5mm M3, 2x 10mm M3, and one M3 nut. I tapped the back hole for the M3 screw to secure the EBM-PAPST RLF35-8/14N blower in place; it also snaps into the shroud. I use a silicone boot and haven't had heating problems at 250C with 100% fan power. However, I'm not sure how that would work without insulation on the heat block. I printed this in PETG at 0.150 mm resolution; ABS will also work fine. If you print with ABS for extra heat resilience, the thread for the probe might be very tight. Screw the probe in and out repeatedly before installing the shroud to widen the thread. The M12x1mm screw mount is designed for a M12 proximity sensor, installed in the same position as 1bigpig's probe mount (http://www.thingiverse.com/thing:2081168). You can find install and setup instructions there. I've also included a M12x1mm nut since the printer can print it perfectly now. The probe is an Omron Manufacturer Part #: E2B-M12KN08-WP-B1 2M, which is PNP and works flawlessly with a 7805 to reduce voltage down to 5V and the PNP Configuration.h of the Marlin duplicator 6 firmware. This probe has a working distance of 8mm in a M12 form factor, translating to about 4-5mm for aluminum. I first tried using an NPN probe but couldn't get it to work; after researching, I also don't understand how an NPN could possibly work with a 7805 wired as shown in thing 2081168. However, all these induction probes have their own integrated circuits that may make a difference. Make sure you have the circuit schematics if you try something different. Detection distance is given in relation to detecting iron; aluminum is much less conductive so the distance is about half. That's why you want the Omrons with double-distance detection. Screw the probe in so it's flush with the bottom of the shroud as a starting point. Instead of setting Z offsets, I just adjust the probe distance by turning it in the thread. This setup works nicely with a 1mm PEI sheet glued on the build plate; there should be enough space for a 3mm glass plate if anyone uses those. The fan on the cooling block is an EBM PAPST 414F AXIAL FAN, 40MM, 24VDC - no vibrations anymore. I've added version 11 without the probe mount. Print Settings: Printer: Monoprice ultimate Resolution: 0.15mm Infill: 35% Notes: PETG at 230C or ABS at 240C, fan at 70% (first 5 layers at 0%)