Ender 3 3DFused linear rail Titan AERO mount and duct

thingiverse

### **Description:** I could not find any E3D Titan AERO cooling ducts for my heavily modded Ender 3 Pro with 3DFused linear rail upgrades, so decided to model my own version with good airflow and good visibility of the nozzle. Additionally I wanted to integrate a small box where I can put connectors for the fans, BLTouch and motors (makes swapping parts a lot easier :D !). Duct was designed to take a single 5015 radial fan and was flow optimized (for simulations and optimization SUNON MF50151VX-B000-A99 fan was used). ### **Compatible parts:** 1. *Printer* - Ender 3 (Pro) with 3DFused linear rail kits (should work with CR10, but this is not tested!). For installation You need to remove (unscrew) the two brass spacers on the 3DFused adapter plate; 2. *Stepper* - Designed to use any standard Nema17 from pancakes up to 60mm; 3. *Extruder* - E3D Titan Aero with standard or any other 4010 cooling fan (*anything larger than 4010 will not fit!*); 4. *Heatblock* - Designed for standard E3D V6 heatblock; 5. *BLTouch* - Optional with removable BLtouch bracket. ### **Design models and variants:** 1. *Mounting bracket V1* - used if You want to use the wire box; 2. *Mounting bracket V2* - used without the wire box; 3. *Duct right* - adjustable parts cooling duct with standard orientation of fan (fan mounted to the right, so the parts cooling fan intake is facing outwards); 4. *Duct left* - adjustable parts cooling duct with mirrored orientation of fan (fan mounted to the left, freeing up space in front of extruder for better airflow, but the parts cooling fan intake is facing the motor); 5. *Duct lash* - additional fixing point for parts cooling duct; 6. *Wire box adapter* - adapter to mount the wire box; 7. *Wire box* - a small box to hide connectors or small breakout board; 8. *Wire box cover* - cover for the wire box; 9. *BLTouch bracket* - adjustable bracket for mounting BLTouch. ### **Models to print:** ##### **Without wire box:** 1. *Mounting bracket V2.stl*; 2. *Duct right.stl* or *Duct left.stl*; 3. *BLTouch bracket.stl* (optional); 4. *Duct lash.stl* (optional / if necessary). ##### **With wire box:** 1. *Mounting bracket V1.stl*; 2. *Duct right.stl* or *Duct left.stl*; 3. *Wire box adapter.stl*; 4. *Wire box.stl*; 5. *Wire box cover.stl*; 6. *BLTouch bracket.stl* (optional); 7. *Duct lash.stl* (optional / if necessary). ### **Necessary hardware:** 1. Mounting bracket V1: + 7 x standard M3 button (dome) head bolt (socket head bolts should work too) + 7 x wide M3 washer (optional, but will increase strength of bracket) 2. Mounting bracket V2: + 7 x standard M3 button (dome) head bolt (socket head bolts should work too) + 7 x wide M3 washer (optional, but will increase strength of bracket) 3. Duct right: + 3 x Ruthex M3 threaded insert (https://www.amazon.de/-/en/ruthex%C2%AE-threaded-Press-fit-plastic-ultrasound/dp/B07ZZHL4RY/ref=sr_1_5?dchild=1&keywords=ruthex&qid=1611425755&sr=8-5) + 3 x standard M3 button (dome) head bolt (socket head bolts should work too) + 3 x wide M3 washers (optional, but will increase rigidity of connections) 4. Duct left: + (the same as for Duct right) 5. Duct lash (optional) + 1 x Ruthex M3 threaded insert + 1 x standard M3 bolt + 1 x M3 washer 6. Wire box adapter: + 5 x Ruthex M3 threaded insert + 5 x standard M3 button (dome) head bolt + 5 x wide M3 washer (optional, but will increase strength of bracket) 7. Wire box: + (none) 8. Wire box cover: + (none) 9. BLTouch bracket: + 1 x Ruthex M3 threaded insert + 1 x standard M3 socket head bolt (button (dome) head bolts should work too) ### **Mounting instructions:** 1. Remove the two brass spacers on 3DFused adapter plate; 2. Install the brass insert in the selected mounting bracket for attaching BLTouch bracket; 3. Attach mounting bracket to adapter plate (use as many bolts as You want - the more the better, but, most likely, You will need at least four to ensure rigid attachment); 4. (if chosen) Attach Wire box adapter (do not forget to install the threaded inserts first); 5. (if chosen) Attach Wire box; 6. (if chosen) Attach Wire box cover; 7. Attach motor and extruder (with cooling fan); 8. Install brass inserts in the selected duct (two or tree if using duct lash); 9. Attach duct to bracket (duct should be on the right side of bracket); 10. (if chosen) Attach additional Duct latch to lower left bolt of the extruder and the duct; 11. Attach parts cooling fan to duct; 12. Attach optional BLTouch bracket and sensor; 13. Do the wiring; 14. Print new and wonderful things. ### **Additional notes:** + BL Touch offset - **0,39 mm** + Optional Duct lash was included in the initial design to provide a third mounting point to increase rigidity when printing at high speed. In practice it is not necessary, except if You are using very high accelerations.