Smart Effector mounts for large fans

thingiverse

I wanted a quieter fan setup for my Kossel XL Plus, which also needed more powerful part cooling. To achieve this, I thought of using a 40 mm fan for hotend cooling and two 5015 radial blowers for part cooling. The goal was to keep the printable area intact without reducing it, so everything had to be tightly packed around the Smart Effector. I found JimboRRs nice design of a fan mount but didn't want to remove the self-tapping nuts at the Smart Effector when changing a fan mount. I modified his design to make it compatible with the existing setup and secure it with a flat nut that fits on the remaining thread below the mount. My version of JimboRRs design tilts the radial blowers by about six degrees around their axis of rotation to avoid contact with the rods at the border of the printbed. The pictures show an earlier version without this tilt. To utilize all three sides of the Smart Effector, I designed a mount for the 40 mm hotend fan using the same connection system as the part cooling fans. This allows it to be mounted on the third side of the Smart Effector. The part has a slot on top to prevent collision with one of the three screws holding the extruder. The nozzle of the radial fans is short to prevent melting, regardless of how the heating block is oriented towards the fans. Since the 40 mm fan needs to go on the only side without connectors, there's only one way to mount this setup. Two words of warning! 1. Combining two 5015 radial blowers for part cooling creates a very powerful setup. If I go above 70% fan speed, my 24V E3D V6 hotend can't maintain its temperature. When dealing with high hotend temperatures, I have to reduce the fan speed even further. 2. The Smart Effector becomes heavier with this fan setup, so in my printer, the currentless holding torque of the motors cannot support it when the printer is turned off. I'm still looking for a solution to hinge the Smart Effector before turning the printer off, so I don't have to move it manually and prevent it from crashing into the hotend. The solution for this problem is [here](https://www.thingiverse.com/thing:2932384). I hope this design meets your needs, and you can use these parts in your printer. **EDIT May 26th, 2018:** I added version nine of the fan nozzle, which has only slight changes compared to version eight. It should blow less against the hotend nozzle. **EDIT April 6th, 2020:** Since the fans were still too noisy, I created wider nozzles so that the fans have less resistance.