YAFS - Yet Another Fan Shroud for Ender 3 (Work in progress)

prusaprinters

[Updates at the bottom]Here is my first go at designing a fan shroud and duct assembly for the Ender 3. I mostly made this for fun but its also functional and someone might like trying it out. Keep in mind that this is a work in progress, there are many things that can be improved. Feedback and remixes are welcome :)Key advantages:- more room around nozzle for different duct designs- provides clear view of the nozzle, great for watching first layer go down or for using an endoscope as a nozzle cam- saves weight, this printed shroud is 25g lighter than the stock metal shroud, so you can still mount a second fan including longer fan ducts without any weight penalty- easier access for cleaning the hot end cooling fan- reuses original hardware (4 additional screws required for using 2 blower fans though)- can be used with either one or two 4010 fans without reprinting anything- more constrained air flow to the heatsink, clear path for the hot air to escape out the sides, not through the bottom like stock- compatible with the old style Creality direct drive bracket and maybe other direct drive conversions too- uses two original screws as well as a hook on the right side for sturdy mounting- easy to print, requires 3 printed partsshortcomings:- ducts as they are currently create a square pattern under the nozzle rather than the air converging into a point.-possibility of strings being sucked into the hot end fan because its not fully enclosed from the bottom, this will get fixed with a protective screen redesign- this is not compatible with any sort of ABL sensor- lacks a strain relieve for the wiringIf you are convinced you want to run this, here is howPrinting:Shroud: I printed mine out of PETG but PLA would probably work as well. Print the shroud standing up with the bottom contacting the bed (so flip it 180 degrees), Print with supports only touching the bed. 0.28 layer height works fine for the shroudDucts: There is only one file for the duct so you will need to mirror it for the other side in your slicer. If you decide to run this with a single 4010 blower fan, pay attention which side you need to print, I printed the ducts out of PLA at 0.20 layer height but the finer the better because of the mounting holes. Print them as they are orientated with supports touching build plate. Maximum overhang on the ducts is around 70 degrees so it might require lot of support material.Screen: Print with the flat side facing down, no supports required. The finer the resolution the better because of the clips.Install: (do at your own risk, im not responsible if you botch it)-Remove your old shroud, remove the fans from it. -Slide the new shroud on so that it hooks on the carriage plate on the right side and holes on the left side line up, then you can bolt it in, be careful with the wires. -Hot end cooling fan is mounted reusing the 4 original screws-attach the 4010 blower fan/s to the shroud using only the original hardware, pay attention to the screws, 2 of them are longer, they go on the bottom. Check if the bottom back screw isnt coming into contact with the wiring.-fan cover clips on to the protruding screws for the blower fansalso, if you want to run this in the dual fan configuration, wire the fans in parallel.Let me know if you have any issues or feedback and post your version if you decide to print it and run it, i like seeing those :)Update1: I accidentally uploaded the old version of the file for the shroud. It works but the newer shroudv3 fits better, sorry about that, it should be fixed nowUpdate2: Unified version of the shroud uploaded. This is an all in one solution, ducts are now part of the shroud. This means less customization but it saves on time and hardware, part cooling fans now simply slot in, but screw holes are still present. On top of that i remove some bits that were interfering with a direct drive bmg mount im running, so its lighter, bit uglier but more compatible. If there is enough interest i will make a unified version of the original shroud as well. Also added to the newest shroud is a BL touch mount, cant test it as i dont use one but someone might find it useful.