Lulzbot Mini 25mm Heatblock fan replacement

thingiverse

Worried by "bad stories" about the standard 5V squirrelcage fan, I planned ahead and ordered a 25x25x7mm 5V fan to upgrade my LulzBot Mini. To make room for the new fan, I designed a custom fan duct that fits snugly into the original fan mount insert using the same hex screw. LulzBot has since upgraded their Mini with an even bigger Heatblock fan. To secure the new fan in place, I used M2x3x3 inserts to mount it firmly on my Mini. For maximum cooling efficiency, I positioned the fan so that it blows directly into the heatsink. However, due to the tight fit of the enclosure at the back, the duct needs a slight rotation (away from the insert) to slide onto the hexagonal heatsink smoothly. BioLumo's 40x40mm version is available online, but I opted to keep my Mini as compact as possible. To access this design and create your own custom fan duct, visit Thingiverse at http://www.thingiverse.com/thing:1587110. Update: After printing the duct, I made adjustments to prevent material from flowing back into the hot-insert pockets by making them a little deeper. Additionally, I widened the screw pocket slightly to ensure a snug fit. Printer Settings: * Printer Brand: LulzBot * Printer Model: Mini * Rafts: No * Supports: No * Resolution: 0.25mm * Infill Percentage: 85% * Notes: To prevent damage, print this duct in ABS material only. Despite exposure to the heatblock's intense heat, I've seen no signs of deformation on my printed version since installation.