Wanhao i3 Backplate w/ 80mm fan

thingiverse

Update 2/28/2017: User JIMBOTRON, http://www.thingiverse.com/Jimbotron, has reinforced the screw hole walls to make them easier to print and install. I have not tested his design, but feel this is a great addition and hence I added to the files here, as he suggested in his remix @ http://www.thingiverse.com/thing:2137022. Look for the file called JIMBOTRON_BackPlate_ScrewHole_Fix01.stl. If I get enough feedback that this version works, I'll deprecate the originals and mark this as the recommended version. I also removed the WIP note as I've been using this for a while now with no issues among others. Update 7/20:16: I made a v2.1 with the power coming out to the right or left side instead of the top for those who asked for it. I still need to fix the screw walls as they don't always print properly. In the screenshot, the red version is this new one, and the white has the plug on top/bottom. Update 6/8/16: I just uploaded v2.1. Fixes: added holes back to the backplate. Extended the plug jack so terminals don't hit the fan. Removed thick wall. Moved plug to left/right sides. Moved fan mount to the side to make more room for the terminals. Shortened the cable port by 17mm as it was WAY too long. Update 6/6/16: Just printed this and noticed that the current v2 doesn't have holes in the bottom for the screws. You could drill the holes but I'll fix this in v3. Also, the power plug, while still on top, still has its connectors sticking into the 80mm fan. I will either extend the back another 15mm to compensate or the user will have to bend the wires for them to fit. I'm going to look at what other options there are and try to rework this. Another issue is that the case requires m3 screws at least 55mm long, which isn't very practical. I'll have to figure out what the options are here. One user just used m3 8mm screws and using a long screwdriver got them in. That's a novel idea that should work just fine. UPDATE 5/19/16. Uploaded v2. Changes: Thicker walls were added around the power connector and cables, making it stick out the top about 6mm (1/4in). This is necessary to compensate for the width of the power connector. I intend to clean up the transition in the future. Wire connector slot was shortened by 5mm, stabilizing the wall and moving cables away from the fan. Cleaned up artifacts on the base of the piece. Moved grille away from power socket by a few mm to give more room. I liked the original, http://www.thingiverse.com/thing:1459929, but I wanted to use a 80mm fan and eventually a 120mm or 140mm if I can fit it. So I remixed the original, added the grille from http://www.thingiverse.com/thing:77363, moved the power cord to the top (for now), and the switch next to it. I'm printing it right now, so this is my first prototype, and I'll update this as it works out or not. Print Settings Printer: Wanhao Di3 Rafts: No Supports: Yes Resolution: .32 Infill: 30% Notes: Update 6/8/16: v2.1 requires supports for the overhanging plug mount. Bumping infill to 30% to stiffen outer walls. Slow down the outer shells as the walls are pretty thin, and make sure you have decent cooling or extend the minimal layer time. PLA would be fine for this. If your using a .6 nozzle like me, the screw walls on the inner side are too thin and won't print with the .6 nozzle. I'll work on making those thicker and therefore printable with a .4 layer height.