EnXlosure AC Infinity HEPA Filter Fan <$50

prusaprinters

Back StoryHoly crap Batman, it was getting loud by my desk, this was due to 3 EIBOS3D Cyclopes filament dryers, the Prusa MK4 with Prusa Enclosure with HEPA filter, and my Prusa XL 5 tool head with EnXlosure and my own mod of the same HEPA filter used in the MK4 enclosure (as well as a buddy mod that has a 60mm fan).  First thing I did was buy several of my favorite <20dBA 60mm fan (the Noctua NF-A6x25 5V ultra quiet fan, 1.3watts) and upgrade all 3 of my Cyclopes filament dryers.  Wowzer, did that make a HUGE difference.  Next I removed the 60mm 24 volt fan (38 dBA) that I put in the upgraded buddy board cover on the back of my XL for better cooling of the boards.  In order to use the same 5 volt Noctua fan (which was 5V), I used my favorite go to small size buck down converter, the LM2596 (I buy those 20 at a time for less than $1 each).  This let me step down the 24 volts I used from the XL to the 5 volts my Noctua fan required, done.  **NOTE** This is NOT needed for the HEPA Fan Mod, it is just info to do with the back storyLet's Get Into ItOK, now on to the loudest fans in the whole set up, those ALVEO3D 120mm blower fans (sold by Prusa as their advanced HEPA filter system).  Now granted they do move a little more CFM and have more moving pressure, but I am good with loosing a little bit of performance for reduced noise and power consumption.  Since Noctua doesn't make blower fans (come on Noctua, pleeeeeease start making them), I looked at my second favorite quiet fan company, AC Infinity.  And dang if they didn't have a 120mm blower fan that was only 17 dBA at 1.1 watts :-O, perfect!!.  The only concern I had was the shape and location of the exhaust outlet.  This turned out to be a blessing once I received it, as I quickly realized that I could remove almost half of my first model that used the Prusa/ALEO3D blower fan.  The other plus was that it was USB powered and came with a 3 speed controller (all this and only $17 and uses only 1.1 watts).Since Prusa sells JUST the HEPA filter pack by itself for under $30 and I stock those as maintenance parts in my farm, I decided to stick with that (you will be hard pressed to get a similar quality HEPA setup for much less than that, though it is possible).  So for both the super quiet blower fan with 3 speed controller and the HEPA filter was $48 (compared to the previous solution which was $114=$76+114 and was a HECK of lot louder).  Another thing I wasn't comfy about, is that Prusa doesn't sell just the blower fan, so in order to stock that, I would have had to get a whole kit.  With this solution, I just have a couple extra of those $17 blower fans from AC Infinity for any maintenance.  I guess I just never noticed the noise before with the farm, because I don't work in there.  But as I have been building out my R&D and prototyping setup, it's right in my office and there is no escaping noise (or VOC's thus the HEPA filters, plus my VOC sensor, and my Austin Air HealthMate Plus.Any way, enjoy, this model prints super good and the assembly is a breeze, just check out the tips and tricks, and consider my suggestions for printing.  Happy printing! Printing Suggestions- I would print this in at least PETG- 4 perimeters, first layer height of 0.2mm and layer height of 0.15mm- 20% infill with the Gyroid fill pattern- I would use Organic supports (with "For support enforcers only" enabled) and either use my .3mf file, or paint on supports under the square 100mm overhang and the round 80mm circle overhang (the circle doesn't have to have the supports, but will be much better shaped if you use organic supports.- I wouldn't lower the Gyroid infill percentage or perimeter number, as there are 10 heat inserts on this part that will be holding up a running fan from a piece of acrylic.What's NeededQTY 1: Prusa HEPA Filter (by ALVEO3D) - $29https://www.prusa3d.com/product/hepa-filter/QTY 1: AC Infinity 120mm blower fan, USB, 3 speed controller, 35CFM, 17 dBA, 5 volts, 1.1 watts - $17https://www.amazon.com/dp/B012CL2V3IQTY 4: rutheX m4 brass heat inserts (m2+m3+m4+m5 assortment of 270)https://www.amazon.com/gp/product/B08K1BVGN9QTY 4: SSm4x8mm pan head machine screws (m4 kit of 601 pieces)https://www.amazon.com/gp/product/B0B29227VQ**QTY 8: SS m3x8mm pan head machine screws (pack of 100)https://www.amazon.com/gp/product/B01BBOZGKC**QTY 8: rutheX m3 VORON (RX-M3x5x4) brass heat inserts (pack of 100)https://www.amazon.com/gp/product/B0CDH36ZMX** You most likely have this many left over from your EnXlosure buildTIPS & TRICKSdue to heat inserts, I highly recommend using 4 perimeters and 20% Gyroid infill, this applies to both v4 and v5the opening (the top layer of the print) is where you will slide the filter out and replacement back in.  The tip here is to install this upright as it is printed.  I don't think the filter would ever wiggle it's way out if you installed downwards, but you never know.use some 100% silicone when assembling and against the acrylic. It's not necessary, but will ensure no suction leaks for max efficiency.I added a small channel around the fan opening for applying an o-ring if you can find one that size OR just do what I did and apply a small bead of 100% silicone and let it cure.  I would say no more than 1mm sticking above the plane of the part would be more than sufficient here.  CREDITMy own model of the Prusa Advanced HEPA Filter for the Prusa XL EnXlosure:https://www.printables.com/model/918797-enxlosure-prusa-hepa-filter-fan-mod