E3D v6 40 mm Fan Duct and Extruder for MakerGear M2

thingiverse

UPDATE 2: After numerous requests for significant changes to the design, I updated the 40mm duct and relocated the mounting to a modified 30mm E3D shroud. The updated design can be found at http://www.thingiverse.com/thing:1165614. This incorporates magnetic couplers and simplifies assembly and removal of the ducts with easy snapping parts together or tugging them apart. I tested the hold and all parts fit snugly, holding well in place. After a month-long printer testing period with no failures, both fans hold firmly while remaining easy to assemble. UPDATE 1: My recent update to the E3D v5 extruder and fan duct at http://www.thingiverse.com/thing:533029 improved the hotend's fit into the extruder significantly, requiring less force for insertion and a tighter fit overall. I adapted these improvements for my E3D v6 extruder to ensure that the hotend inserts without difficulty, ensuring reduced play and resulting in enhanced print quality due to reduced warping of the nozzle. Additionally, I renamed the part with a 2.0mm ID PTFE upper opening to accurately reflect its inner diameter. To design this, I referenced my model for the E3D v6 at http://www.thingiverse.com/thing:433258. Due to the design's appealing fit and functionality, I approached it differently from that of version 5, utilizing more modern methods while still maintaining traditional components. This allows for a wide range of compatibility with other existing components and future updates. This new duct is designed with the M2 frame in mind but does have some constraints given the tight space it operates within. To address this, I maximized the distance between the rim of the duct outlet and the hotend heater block without compromising fitment. In doing so, adjustments were necessary for both angle and width to balance airflow correctly. When using high cooling rates, heat creep issues can occur, though these challenges have been solved through consistent use in a controlled environment. Large PLA print projects benefit significantly from this setup, tackling big retraction zones without experiencing the heat creep often seen during these types of prints. Design suggestions or fixes are welcome. Based on demand, I will consider adapting this design for version 5 of the E3D. To assemble: - Firmly press the hotend into the extruder. - Use an 18mm M2 bolt and nut to secure the duct onto the extruder, with the heater block oriented away from the 40mm duct to minimize warping. A setting of less than 50% on the fan has been optimal in most instances for minimizing warping during prints.