R2-D2 Ventilated Battery Boxes for Mr. Baddeley 3D-Printed Droid

thingiverse

So check out this quick video featuring my battery box mods: https://youtu.be/HXRzNNS9hTo I built these boxes after my droid's drive gear overheated and melted within 30 minutes of heavy use due to a lack of cooling in the previous design. I also swapped out the drive gear for nylon, which has a higher 250C print temperature compared to PETG. The new battery boxes come equipped with a false-back output vent that pays homage to the astromech design philosophy. Currently, they're powered off the 24V drive system and have a separate switch to turn them on and off. I'm planning to modify them so they activate automatically when the battery box or motor case temperature reaches a certain threshold, thereby conserving power by only running them as needed. To make maintenance easier, I added clips that allow the boxes to be quickly attached and detached without tools. These clips use 24V 20mm fans from Amazon (https://www.amazon.com/gp/product/B01MU4PU9K/ref=oh_aui_detailpage_o07_s00?ie=UTF8&psc=1), which are mounted using M4 25mm bolts. The back air duct panel is secured with #4 1/2 inch wood screws, while the clip uses embedded 4mm square nuts and 20mm M4 bolts. I've also included vents for air intake behind the battery straps, but I chose to block them off with an included plate to ensure more airflow near the motor. In addition, I plan on adding some cooling fins to the motor case for extra heat dissipation.