Small, light, effective fan shrouds for popular hotend designs This has been moved from another thread where some optimisation of combined hotend coolers/part fan shrouds were being revisited. So far we looked at e3d v6, e3d volcano and came up with one piece, printable dual part fan, single heatsink fan coolers, which are small and light. They do work air comes out quite nicely, and they fit within the limited mass/space on delta/corexy printheads. Started off with this design http://www.thingiverse.com/thing:780379 Which is nice but takes up way too much space for a delta effector. I saw this volcano fan by Jinx http://www.thingiverse.com/thing:1676276 and decided to copy the principle but make it much smaller (and for v6 rather than volcano) My remix for E3d v6 fan shroud http://www.thingiverse.com/thing:1692742 Jinx's version - prints better, uses a bolt to secure not cable/zip ties. http://www.thingiverse.com/thing:1693413 I have also moved on to try one for volcano also [attachment 82493 supercompacte3dvolcanotwin30mmfanshroudrepairedwindows.stl] Which I have not published as I don't know if it works yet. But it would be nice to see what other ideas are out there and see if modifying these designs can come up with the smallest, lightest, relatively most effective twin fan cooler for these hot ends. https://reprap.org/forum/read.php?1,699351,699351#msg-699351 Tue, 15 Sep 2026 18:03:01 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?1,699351,797626#msg-797626 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,797626#msg-797626 Mechabits%2B%2B0761.JPG
MechaBits%2B0596.JPG
Mechabits%2B0680.JPG
Not as small as I would have liked 68g, but after many reworks I couldnt face another iteration, 2mm screws are a pain but was thinking of melting some filament to secure the radials, not sure if i need some extra ducts/part. Mulled over multipart version, which may have been better in a few ways, it's really satisfying to also do it in one. I would like to see how if printed in other materials how it could be smaller /thinner, lighter....and or done totally different.]]> MechaBits General Thu, 23 Nov 2017 00:12:17 -0500 https://reprap.org/forum/read.php?1,699351,795933#msg-795933 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,795933#msg-795933 dc42 General Sat, 11 Nov 2017 03:28:18 -0500 https://reprap.org/forum/read.php?1,699351,795929#msg-795929 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,795929#msg-795929
IMG_20171111_012214.jpg
[/url][/img]
]]> Hamel General Sat, 11 Nov 2017 02:36:03 -0500 https://reprap.org/forum/read.php?1,699351,795563#msg-795563 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,795563#msg-795563
If my theory is correct, a narrower inlet may lower maximum air intake into the fan, but will reduce back pressure and allow more air to be kept inside where it will be forced out the outlet. It is an interesting idea, and one that will have to wait till I get a working model! Does anyone have any idea how I can measure cfm?

Anyway... progress! The body sits on an E3D V6. its a tight fit so may need a slight sanding, or tweek your extrusion. It should be a tight fit to stop rotation. It takes a standard 30mm fan to cool the cold end, which is secured with 2x plastic screws and the 2x 30mm blowers are secured by 4x M2 screws and 4x M2 heatpress brass inserts. If its wanted, I will release a version that doesn't need brass inserts but you will still need M2 screws for the fans (unless you drill them out). The ducts are printable without support if you have good bridging. It also takes an optional DC42 IR sensor.



I think this will be the winning design! I'm quite happy with it so far. Next up I need to test if a wide or narrow outlet is best on the duct.

Edit :



]]> Origamib General Wed, 08 Nov 2017 10:51:35 -0500 https://reprap.org/forum/read.php?1,699351,795037#msg-795037 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,795037#msg-795037
uses 3 x 25mm fans, and small print cooling ducts. Compact, lightweight, quiet, powerful, simple.

[attachment 99391 G3Cooler.jpg]]]> Mutley3D General Sat, 04 Nov 2017 16:39:24 -0400 https://reprap.org/forum/read.php?1,699351,795032#msg-795032 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,795032#msg-795032 ESTIMULO General Sat, 04 Nov 2017 16:04:00 -0400 https://reprap.org/forum/read.php?1,699351,794983#msg-794983 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,794983#msg-794983
Fan shroud designs

This has mounts for 40 and 30mm fans, as well as one for a 4mm pipe duct if you use pressurised air. I've only really tested the 40mm, but I will soon have the 30mm up and running and will update as I know more. If you do happen to test these, let me know! i'd love to collaborate on new designs, or even just to see this out in the wild.



]]> Origamib General Sat, 04 Nov 2017 08:43:00 -0400 https://reprap.org/forum/read.php?1,699351,794351#msg-794351 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,794351#msg-794351 DjDemonD General Mon, 30 Oct 2017 10:28:51 -0400 https://reprap.org/forum/read.php?1,699351,794346#msg-794346 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,794346#msg-794346 cwaa General Mon, 30 Oct 2017 09:45:18 -0400 https://reprap.org/forum/read.php?1,699351,794266#msg-794266 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,794266#msg-794266 ESTIMULO General Sun, 29 Oct 2017 14:34:08 -0400 https://reprap.org/forum/read.php?1,699351,781973#msg-781973 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,781973#msg-781973
http://www.delta-fan.com/ProductSeries.aspx?seriesname=BFB]]> blt3dp General Sun, 06 Aug 2017 03:06:05 -0400 https://reprap.org/forum/read.php?1,699351,781146#msg-781146 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,781146#msg-781146 nebbian General Mon, 31 Jul 2017 22:54:00 -0400 https://reprap.org/forum/read.php?1,699351,768493#msg-768493 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768493#msg-768493
Quote
drmaestro
I also have this issue and I am trying to find a suitable compact solution for cooling. My current design uses rails and they tend to collide with the part cooling fan with the existing designs where the fan is tilted upwards. It seems I require a blower fan solution which can have a direct downwards output. I ordered a couple from Aliexpress but the seller cancelled them and told me they were too old to be sent, so not brand new. They were the only 30 mm ones working at 12 volts, the others generally work at 5 volts. Where do you source your blower fans from? What happens if you give 12 volts to a 5 volts fan? Does it start rotating 2 times faster? DjDemonD, I might go for your Sunons if you are happy with them (I also want to try your piezo solution, so maybe both of them can be handled in the same shipping?

I think I've only got one spare now. But dhgate had them in packs of 10. You can order a piezo sensor module from the website it's in my sig. If you want the fan with it PM me.]]> DjDemonD General Wed, 17 May 2017 04:58:52 -0400 https://reprap.org/forum/read.php?1,699351,768463#msg-768463 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768463#msg-768463
Quote
drmaestro
What happens if you give 12 volts to a 5 volts fan? Does it start rotating 2 times faster?

I'm not sure about any of the other ones, but the sunons seem quite happy at 12V, they push out quite a bit of air for their size. You can throttle them down to less than 10% duty cycle and they just tick over slowly. Never had one fail on me, whereas I've had many of the normal sleeved bearing axial 30mm fans give up after a month or two.]]> nebbian General Wed, 17 May 2017 00:53:14 -0400 https://reprap.org/forum/read.php?1,699351,768455#msg-768455 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768455#msg-768455 drmaestro General Tue, 16 May 2017 19:54:06 -0400 https://reprap.org/forum/read.php?1,699351,768183#msg-768183 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768183#msg-768183
They seem to work for me. I tried a fishtank pump and made a copper tube, it was noisy and didn't deliver anything like the air flow I was expecting. That being said maybe my version just wasn't very well done, maybe genuine BerdAir is better.]]> DjDemonD General Mon, 15 May 2017 12:09:14 -0400 https://reprap.org/forum/read.php?1,699351,768181#msg-768181 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768181#msg-768181
I'll post all my finds in here, and edit this post as I find them.

B0503AFB2-8 -- 30x10mm fan, 5v --- The cheapest and available in bulk at around £4-5 a unit (incl. P&P)
GB0503PFV1-8 -- 30x10mm fan, 5v
B0503PFB1-8 -- 30x10mm fan, 5v --- These 3 are often found 'second hand' taken from new salvaged equipment. BA03010B05U is considerably more powerful.
BA03010B05U -- 30x10mm fan, 5v

RFB2008 -- Frickin' tiny. Available from lulzbot, and not really anywhere else. 5.5v and measures 25x20x8.5mm. Delivers a respectable 0.6 cfm (for its size). Micro blower
RFB2008N -- No idea where these are sold, apparently found in mini projectors? comes in 5v and 3.3v varieties

UDQFNKH01 -- 35x10mm fan, 5v -- Metal design and apparently 80'000 hours life (5015 blowers are usually rated around 40'000 hours). used in notebooks. Usually priced between £5-15. not a bad choice??]]> Origamib General Mon, 15 May 2017 12:05:36 -0400 https://reprap.org/forum/read.php?1,699351,768177#msg-768177 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768177#msg-768177
DJDemonD has recently got some, perhaps he could chime in?]]> nebbian General Mon, 15 May 2017 11:39:02 -0400 https://reprap.org/forum/read.php?1,699351,768132#msg-768132 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768132#msg-768132
I've been looking into the CFM of fans / pumps and it seems that a decent fish tank air pump will deliver about 0.3 to 0.4 cfm, where as these small fans deliver around 1 cfm. I'm starting to think there is more to air pumps then people are giving credit for... If it is delivered accurately it should not matter about having less cfm.... especially since most fans are inefficient at delivering air, where as the air pump should in theory deliver all the air. I've got some 4mm OD brass pipe that should work really well. It's easy to use and bends easily by hand... Will have to do some more experiments I think!]]> Origamib General Mon, 15 May 2017 08:33:07 -0400 https://reprap.org/forum/read.php?1,699351,768131#msg-768131 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768131#msg-768131
Quote
shortyski13
Do you think the cooling scheme in this design will work well, or do you think 2 fans on either side is really needed? (Pictures attached). Essentially, I upgraded the 30mm fan on the V6 hotend heatsink to 40mm and ducted it, just to give that some extra cooling and help prevent creep at higher temperatures, and then used the stock 30mm fan that comes with the hotend to blow fan on 2 sides of the nozzle/filament via ducts. The idea was to save a couple bucks (please don't argue this point of it, as it isn't the point of the question) and not have to buy 2 blower fans. Also, while it is a bit bulkier, due to the design of my printer, it actually does not take away from my print area.
[attachment 94115 Hotend_Cooling.PNG][attachment 94116 Hotend_Cooling2.PNG]

Narrow air exits create high pressure, yet most radial fans are not designed to blow at high pressure (specced at mm or in H2O) and are very inefficient. A better design would incorporate centrifugal fan.

Like this one: [www.thingiverse.com]

]]> newbob General Mon, 15 May 2017 08:31:40 -0400 https://reprap.org/forum/read.php?1,699351,768053#msg-768053 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768053#msg-768053
Quote
Origamib

I've given up on fans for now.... I never found a decent solution other then a 50mm blower fan. Anything smaller seems awfully designed, or ridiculously expensive. The 40x10mm fans I hooked up are good, but they still add considerable bulk to the hotend that I'm not happy with. The design of the fan is such though that they have a lot of backflow and I wonder if they even push as much air as advertised. I may give one of these air pumps a try still.......

Have you investigated these ones?
B0503AFB2-8



I'm really happy with them on my builds.
]]> nebbian General Sun, 14 May 2017 22:47:37 -0400 https://reprap.org/forum/read.php?1,699351,768028#msg-768028 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,768028#msg-768028
Quote
shortyski13
Do you think the cooling scheme in this design will work well, or do you think 2 fans on either side is really needed? (Pictures attached). Essentially, I upgraded the 30mm fan on the V6 hotend heatsink to 40mm and ducted it, just to give that some extra cooling and help prevent creep at higher temperatures, and then used the stock 30mm fan that comes with the hotend to blow fan on 2 sides of the nozzle/filament via ducts. The idea was to save a couple bucks (please don't argue this point of it, as it isn't the point of the question) and not have to buy 2 blower fans. Also, while it is a bit bulkier, due to the design of my printer, it actually does not take away from my print area.
[attachment 94115 Hotend_Cooling.PNG][attachment 94116 Hotend_Cooling2.PNG]

I would print the attachment to the heatsink aswell and make it into the design, rather than convert the E3D heatsink clip. They do get looser over time and you may find the extra bulk makes it quite loose. I have to ask though, do you need a 40mm fan on the heatsink? I can't say I've ever felt the need for it... Also, the part cooling duct is pushing air onto the nozzle rather then the print. The duct opening needs to angle down more.

I've given up on fans for now.... I never found a decent solution other then a 50mm blower fan. Anything smaller seems awfully designed, or ridiculously expensive. The 40x10mm fans I hooked up are good, but they still add considerable bulk to the hotend that I'm not happy with. The design of the fan is such though that they have a lot of backflow and I wonder if they even push as much air as advertised. I may give one of these air pumps a try still.......]]> Origamib General Sun, 14 May 2017 17:39:12 -0400 https://reprap.org/forum/read.php?1,699351,767827#msg-767827 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,767827#msg-767827 DjDemonD General Sat, 13 May 2017 16:45:04 -0400 https://reprap.org/forum/read.php?1,699351,767769#msg-767769 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,767769#msg-767769 [attachment 94115 Hotend_Cooling.PNG][attachment 94116 Hotend_Cooling2.PNG]]]> shortyski13 General Sat, 13 May 2017 11:54:08 -0400 https://reprap.org/forum/read.php?1,699351,765512#msg-765512 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,765512#msg-765512 Origamib General Tue, 02 May 2017 11:19:19 -0400 https://reprap.org/forum/read.php?1,699351,765508#msg-765508 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,765508#msg-765508
[attachment 93663 thumb_IMG_6187_1024.jpg]

[attachment 93664 thumb_IMG_6190.jpg]

I do like using the cube design for mounting things around the heatsink. Unfortunately this design didn't work for me, as the distance between the effector and nozzle was too great (delta, effector tilt, etc). I redesigned it without putting this into service.

The 30x10mm Sunon fans are excellent: small, light, and push a lot of air.]]> nebbian General Tue, 02 May 2017 11:14:00 -0400 https://reprap.org/forum/read.php?1,699351,765484#msg-765484 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,765484#msg-765484
This mount shaves off around 20-30mm of width compared to the last mount, and requires no mounting screws / clips. It is simply a circular mount that you slip on, and then becomes sandwiched between the heatsink and extruder. I've had no problems with a titan so far, and I imagine it will work with most groove mount systems. The fans will need 8x m2 screws, and the heatsink fan uses the existing e3d plastic screws.

The fan shrouds themselves are fairly basic, they sit about 2mm away from the heat block at the closest, and 1mm higher then the nozzle tip. This is about as close as you'd want to get to deliver airflow I think. The openings of the shroud sit below the heat block, so it shouldn't cool it too much but I'd still probably suggest a silicone sleeve or other insulation if you plan to push these... My experiments with these fans in the past show that anything above 30-40% will cause thermal runaway. good ducting and insulation has solved this for me though, and I can comfortably push them at 100% (as long as you're not too close to heat bed of course.)




The mount so far has been printed and works fine but need to test the shrouds. If there's interest in this I'll release the files.
]]> Origamib General Tue, 02 May 2017 09:17:35 -0400 https://reprap.org/forum/read.php?1,699351,765275#msg-765275 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,765275#msg-765275
Quote
cwaa
I have only been printing for about 1 1/2 years, but still haven't used a cooling fan. Why do you use them?

Are you able to print a 3DBenchy w/o cooling fans? Maybe at lower speed I could but printing at 40mm or higher, with PLA, I need a fan or bow gets uneven. I also get less oozing with cooling fans.]]> newbob General Mon, 01 May 2017 11:14:52 -0400 https://reprap.org/forum/read.php?1,699351,765001#msg-765001 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,765001#msg-765001 Origamib General Sat, 29 Apr 2017 15:33:04 -0400 https://reprap.org/forum/read.php?1,699351,764998#msg-764998 Re: Small, light, effective fan shrouds for popular hotend designs https://reprap.org/forum/read.php?1,699351,764998#msg-764998 cwaa General Sat, 29 Apr 2017 15:09:53 -0400