Layer cooling fan duct for Da Vinci 1.0 3D printer with the E3Dv6 mod

thingiverse

After installing the E3Dv6 hot-end on my Da Vinci 1.0 printer using Thingiverse model #707530, the next logical step was to design a suitable active layer cooling fan for PLA (and also for ABS when really necessary). Initially I tried modifying existing designs with varying success before figuring it would be better to start from scratch and create a custom fan duct that blows as close as possible to the nozzle tip rather than all over the bed. I came up with this design, using a 50mm 5v fan powered by the wiring of the stock extruder fan (with some 12v input source powering the E3D's fan directly), allowing for speed control via gcode. No tests were run to compare against other layer cooling designs but it seems to have a pretty nice airflow - I'm quite impressed! Additionally, this model doubles as an extruder stabilizer, fitting snug under the stepper motor and acting like a wedge that strengthens the set even further. Instructions This model is FDM friendly and can be printed without support structures on its flat side (where the fan is attached). There are challenging overhang angles but nothing that can't be achieved with proper printer settings. The only required supports are near the tip opening for sliding in the belt, but I've already added those to the model. I printed mine on ABS at 0.2mm, 30 mm/s and 50% infill. Push down on the belt a little before inserting the duct, twist gently, then slide the belt in through the opening while moving the print head left to right several times to ensure no contact with the belt or rod. Otherwise use a small file or sandpaper where necessary. Optionally you may also cover the opening with kapton tape. Note that the fan duct has only about 1-1.5mm clearance when the bed is at Z=0, making the screws for securing contact pads on front corners of the bed touch it while printing nearby. Consider replacing those screws or as I did use zip-ties, a far cheaper and simpler solution - see pictures. Also keep in mind that if you're printing something with significant curl up potential then there's also a chance the duct will hit it causing damage.