Part Cooling Duct for Tevo Black Widow & 40mm Fan

thingiverse

Note: The "Standard Version" can be found here: http://www.thingiverse.com/thing:2217394 This part cooling duct and nozzle is designed for use with a Tevo Black Widow 3D printer and a 40mm fan. A file for a compatible velocity stack is also included. With the right duct and fan, and velocity stack combo, you can boost the airflow through the system, giving your parts maximum cooling and better printing. I aim to make all my designs elegant, efficient, and effective - the 3 Es! Feedback is always welcome. I tried many cooling duct systems, but I found that "adriansm's" design (http://www.thingiverse.com/thing:1964762) was the only one that worked. However, after a while, the tight fit and thin walls of this duct started to melt and distort. It was time for an improvement. It was time to design my own cooling duct. Using my knowledge of aerodynamics, I felt I could not only design a more resilient duct but also a more efficient version as well. Using gentle curved surfaces and an internal fan hub fairing, this design keeps the air moving in a laminar flow while providing a connection to the print bed without support printing. It's a win-win design! Please give this one a try; you won't be disappointed. When connecting any layer cooling fan, follow the Black Widow "Community Guide" in Section 11.6.2 and connect your fan wires to the "FAN" terminal on the MKS 1.3 or 1.4 board. When setting up your slicer, the cooling must be off for the first layer and set to reach your slicer's maximum flow at about 0.6-1.5mm layer height. Keep in mind that fans from different manufacturers come in different flow rates. This means all layer cooling ducts will reach a point of "thermal runaway" if you pump too much air through them. To prevent thermal runaway, increase the layer height at which the fan kicks in at 100% and/or reduce the power going to the fan and/or put a sock on the heating block. If you are still getting a thermal runaway at 100% fan speed and have increased the 100% layer height beyond 1.5mm, and you do not wish to use a sock on your heater block, follow these steps: Pre-heat your bed and extruder to your normal operating temps as if you were preparing to print. Perform an auto home. Set the Z-axis height to 0.8mm. Perform a "PID auto tune". (See BW CG) Add 0.2 to the I value and add 10 to the D value. Note: adding these values helps the board adjust more quickly, allowing for extra cooling produced by the layer fan. Set the extruder PID values. Using the selector knob go to Main/Control/Temperature/Fan Speed. Set the fan speed to "100". Note: the maximum for this setting is 100%. If you know the fan is super strong like the Sanyo San Ace 40 9CRA0412J508, start the fan speed at 5 and increase by 1. Use 3 instead of 12 in the equation. This design has been tested without a sock with several cheap fans and has never produced a thermal runaway situation with a fan at 100%. However, six people out of 1500+ downloads have claimed this duct will "always" produce a thermal runaway. More users have said this is the "best cooler ever," which it is not. This design is a design that you can print without a layer fan so you can print a better layer fan like the "Evolution" series. If a thermal runaway is encountered using this layer cooler, post a comment here and I will help you. Posting any issues concerning this layer cooler in the Black Widow Facebook group will quickly attract the attention of one particular "troll" who will give the wrong advice; in which case, I cannot help you. Compatible with: http://www.thingiverse.com/thing:1937278 Use a 4mm nut and bolt to secure to mounting plate. Thanks to adriansm for the inspiration and mounting design. Please check out my other thingis! Print Settings: Printer: Tevo Black Widow Rafts: No Supports: No Resolution: 0.2-0.25mm layers Infill: 35% Notes: Set top, bottom, and sides to at least 1.2mm How I Designed This: Designed on Rhino 5 from scratch using vast knowledge of aerodynamics and aircraft design.