Duet Maestro (& Others) Enclosure with Fans (Rework)

thingiverse

**MAJOR CHANGES LISTED AT THE BOTTOM!!** **Comments are greatly appreciated!** This is a remix of @ktapper's lovely Duet Maestro Case. It was inspired by @Ajlockhart's "Extra Vents" case. Although they're both nice, neither addressed the airflow properly, IMHO, so I reworked it. A BIG shoutout to @ktapper for supplying the original CAD file in his post so I didn't have to wrestle with editing a mesh file!! Major changes: 1. Smoothed the airflow in the intake vent (front) to reduce turbulence. 2. Added vents on the side for better cooling of the main board area. 3. Added a second wall to direct most of the intake air under the drivers, the only part of the board that really needs cooling. 4. Reworked the original wall to allow a path out to the exhaust fan. This should cause most of the air to flow smoothly front to rear under the drivers. 5. Enlarged the front & rear vents a bit. Minor things: I haven't printed this yet! I did slice it in Cura 4.0 and it looked fine, long print with .2 Layer & .4 nozzle (over 10 hours) due to the details. There is a lid posted in the Comments section of the original by @ktapper: https://www.thingiverse.com/thing:3225542/comments I intend to post a lid of my own design for this soon. THIS IS DESIGNED TO WORK WITH A LID! Not having one will significantly impact the airflow! As I see it (without some smoke tests to be sure), the major airflow is from front fan to rear fan across the drivers. A secondary air flow will move from the vents across the board to the exhaust (partially driven by the suction the primary airflow path creates). The upper front vent hole also helps. Just as an aside, the Maestro works fine with the fans I used. **EDIT 4/5/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered a problem (remember, this is a remix). The screw holes for the fans were too big! I reduced them to 2.75mm which should allow tapping (or just screwing in) 3mm screws. **EDIT 4/6/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air channel below the board was not optimized for airflow. I reworked it to improve airflow under the drivers. **EDIT 4/7/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were not properly secured. I added some screws to secure the fans in place. **EDIT 4/8/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/9/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/10/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/11/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/12/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/13/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/14/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/15/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/16/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/17/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/18/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/19/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/20/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/21/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/22/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/23/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/24/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/25/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/26/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/27/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/28/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 4/29/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 4/30/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/1/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/2/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/3/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/4/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/5/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/6/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/7/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/8/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/9/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/10/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/11/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/12/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/13/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/14/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/15/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/16/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/17/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/18/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/19/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/20/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/21/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/22/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/23/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/24/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/25/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/26/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/27/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/28/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/29/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. **EDIT 5/30/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The air flow was still not optimal. I reworked the design to improve airflow under the drivers. **EDIT 5/31/19** Minor change. After printing again with changes (used eSun PLA+, .6 Nozzle, .4 Layers, 2 Walls 20% Infill) I discovered another problem (remember, this is a remix). The fans were still not properly secured. I added some more screws to secure the fans in place. You get the idea. Is there something wrong with this?