prusa i3 Zonestar p802 fan duct upgrade

thingiverse

ok, skipped a few experimental versions now up to v10 latest version modeled with cfd to improve cooling at the extruder head tip. i have managed to print some very small delicate parts as a result, and the quality is definitely better. the design blows air from both sides with a slight asymmetry in order to get the 2 paths closer to the tip. there are supports in the model that improve printing of the v section under the fan, designed for 0.3mm nozzle diameter, worked quite well, easily removable with knife or cutters. previous versions upgraded fan cooler head, supposed to work like an air amplifier, think it works well, consistent cooling all round head (the original only cooled from one side). v5 now uploaded, massive increase in airflow compared to v4, can reduce fan speed as a result. one thing to beware of is having had to move the x endstop as the cooler can now hit the z lead-screw otherwise, pictures in blue. x carrage endstop added. printed x endstop mounts on 40mm extruder cooler fan, stops wider fan duct from hitting z lead-screws without modification. apologies to anyone who downloaded v3, it should have been v4, stl was out of date, fixed now. tip if you're printing this and your prints are stringy then you'll want to pick them off before it covers the top layer otherwise hard to clean out internals. i experimented with cutting supports/nozzles out of the ring and increased airflow but not sure if worth effort. printed in pla to protect against melting, put foil tape on it to reflect heat from extruder, may not be necessary but thought worth effort. put picture of v2 with cut holes showing added foil tape, v4 (in stl) is much better for airflow and footprint.