Zonestar D805SR2 (Z5R2) Centrifugal Blower Layer Fan Mount and Duct

thingiverse

This is a custom-designed fan mount and duct inspired by the Prusa Mk3's, specifically engineered for replacing the default layer cooling fan included with the Zonestar D805SR2 (Z5R2) with a powerful 5015 centrifugal blower. The standard 40mm fan struggles to produce much pressure, resulting in air blowing back out of the duct rather than through it due to this limitation. Additionally, the existing duct fails to direct air towards the dual nozzles at all, as it was originally designed for single extrusion. This upgrade addresses both issues by providing an easy way to mount a 5015 centrifugal blower and directing air towards both nozzles effectively. Please note that there's no complex geometry involved here, as I'm currently restricted to printing with PLA and don't feel comfortable testing out designs that get too close to the heatblocks or hug the nozzles for omni-directional cooling. This duct can be printed in PLA and will safely direct air towards the nozzle tips without any issues. You can reuse the old layer fan mount screws, and there should be a spare M3x30mm screw included with the printer that you can use to secure the 5015 blower (which you'll need to obtain separately). To install, first attach the middle part of the mount to the hotend shroud without tightening it down. Then, insert the screw through the duct and screw it into the leftmost screw hole on the mount. Tighten both screws and insert your 5015 blower into the duct, which should fit snugly. Finally, insert a long screw (M3x30 should work) through the bottom right screwhole of the blower and secure it with a M3 nut. I'd like to extend special thanks to the reddit 3D printing community (specifically the amazing people at r/fixmyprint) for advising me to replace that fan as soon as possible (although I took a whole month to finally get inspired to take action). Note that the mount is quite small and fragile, and the duct still has room for improvement. I may update this design with better-designed parts in the future.