FLSUN plus dual duct part cooling fan w/ relocated SN04-N auto level sensor

thingiverse

I've tried several part cooling fans, but most blocked the nozzle's view or provided inadequate cooling. Ackmaniac's fan has worked well for me, except when printing small parts with quick layer times, where I needed more cooling on the right side. This solution addresses that issue. If you have the left duct installed, I've remixed the right duct to fit snugly behind it. The "shroud/sensor mount" and "fan mount/shroud extension" then sandwich everything together. The hotend shroud provides a convenient spot for tucking away the auto-level sensor, and I've added lower sensor holes for printing on glass. Loosening the two front screws might be necessary to give some wiggle room for slipping in the right duct, but you shouldn't have to remove them entirely. The shroud sides are held together by a thin piece. If it breaks apart, the screws will still keep everything in place. I recommend gluing the shroud to the shroud extension before assembly to prevent breakage and make assembly much easier. This two-piece design allows for easy printing without supports. The duct has built-in removable support, and I've added nut holders to the back of it for those pesky nuts at the front of the X carriage that tend to fall out when you change things. Print all three pieces with the fan flange facing down on the bed, so you may need to rotate them in your slicer. If you only have one duct, orientate the shroud so the bottom edge of the level sensor mount is pointing towards your existing part cooling fan by rotating the Z axis in your slicer. The same goes for the cooling duct – overhang it towards the fan. All holes are sized to be used without nuts (4-M3x25 through the hotend fan, and M3x20's that are a tad short but will work fine). However, my original holes were too small and needed to be enlarged slightly (a 1-60 wire drill set is very handy to have). I've resized all of the holes, but haven't printed them yet to test. After gluing the shroud to the extension, chase all of the holes with a M3 screw before assembling the rest. The wires for my hotend are on the left, and I had to rotate the extruder slightly to get the sensor mount through and over the top of the wires. Be sure to secure the sensor and hotend wires away from the wheels. To make things more confusing, I printed the extension with three layers of black, a few layers of green, and the rest in orange. The goal was to allow the green to show through the "FLSUN" logo, but the letters were too small. I've enlarged them in the included file, as well as one without the FLSUN logo. PROBE OFFSETS Y +22 X +25 Enjoy.