Replicator 2X active cooling fan duct - side discharge

thingiverse

This active cooling fan solution for Replicator 2X is similar to ten13th's design and doesn't require a custom fan guard. Its duct geometry optimizes airflow towards the work-piece, with easy installation using two long hex bolts from the extruder and securing the fan to the duct with bottom screws. The fan has a smaller profile than front-discharge designs and is powered externally. Side-discharge fans are more efficient due to good inflow/outflow cross-sectional areas, making them ideal for high airflow demands like small or detailed PLA prints. Print parameters include laying the model with intake facing down, exhaust up, and hex bolt holes angled 20 degrees from horizontal. ABS 0.2mm layer thickness with 0.3 infill density is recommended, along with rafts and supports at 55-degree angle with 0.2 density. Additional parts include a Digikey part #603-1363-ND 40mm 12VDC blower fan, a 12VDC household power supply, and an optional switch. Assembly involves removing rafts and supports carefully, replacing extruder hex bolts with duct ones, securing the duct to the head, connecting wires and mounting the fan on the duct. A warning is given about potential relay failure when using Makerbot's cooling fan relay, recommending an external power source for safety.