HUSH! Quiet cooler for Ender 2 / 3

thingiverse

<h2>Design goals:</h2> Quiet! Better part cooler Better hotend cooling Low weight Easy access to nozzle Good visibility of nozzle with LED Compact Modular No supports Compatible with my Direct Drive solution EDL https://www.thingiverse.com/thing:4642537 <h2>Design choices hotend cooler:</h2> 50x50x15mm axial fan + resistor (quiet) Pressure booster (axial fan has low pressure) Adjust fan speed to same or better performance as original <h2>Design choices part cooler (Claw 1):</h2> Single radial fan 5015 Cooling from two directions CFD calculations with Simscale. Note that the flow from a radial fan is not pedicular to the fan outlet (~20 degrees) and the flow is much higher on one side. Water test was needed to balance flow in right and left channel. <h2>Result:</h2> Noise reduced 11dB! Same hotend cooling performance as original (measured inside heat brake) 5015 can be removed in 2 sec (hold in place with elastic band) Part cooler is mounted with two M3x12 screws. Everything can be removed with the two original screws <h2>Parts:</h2> Gelid 5 (50x50x15) fan (spec 12.9CFM/4000rpm@12v) Resistor hotend fan 36ohm (I used 18+18ohm on positive led) JST XH 2.5-2 connectors (for connecting fan to motherboard). Check polarity of connector. Hair rubber band for 5015 Two screw M3x12 2 for part cooler Two 5 mm LED + resistor 330 ohm Radial fan 5015 <h2>Note on material:</h2> I used both PLA and ABS. ABS is recommended. Part cooler in PLA may deform if part cooler fan is turned off. Aluminum tape might help. <h2>Note on axil fan:</h2> Actual voltage at HE fan with 2x18ohm was 8.6v and speed 3630rpm Pressure booster on HE increased airflow ~8% Spire 50x50x15 4800rpm@12v did not work well. Rattling noise when mounted on x-axis (bearings can’t handle vibrations from X stepper motor) Gelid 5 (50x50x15) worked fine. Start duty cycle ~20%   <h2>Note on radial fan:</h2> NoName 5015 fan didn’t sound good at any PWM speed than 0% or 100% so I changed Marlin firmware to software PWM. <h2>Note on pressure booster:</h2> The wings is only one wall thick so make sure to use "Print Thin Walls" in Cura. How to measure static pressure: https://www.thingiverse.com/thing:4401775 <h2>2020-12-10: Minor update</h2> Reinforcement at coupling moved (for more space) Ender-3 V2 support added (not tested) <h2>2020-12-12 update:</h2> EZABL 18mm mount (and 12mm with EZABLMini_18mmAdapter) added on request (not tested). Distance from nozzle x=43 y=-2 BLTouch v3.1 mount added on request (not tested). Distance from nozzle x= 24 y= 3 Distance heater block to Bltouch side 7.5mm (to close?) <h2>2021-02-03: update</h2> Ender-3 V2 support removed beacuse of problem with Bltouch