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Orca v.2 40mm print fan mount

by Tunako, published

Orca v.2 40mm print fan mount by Tunako Oct 15, 2011
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Summary

Mount for an 40mm cooling fan. Fits on an Orca v 0.2 with V9 Hotend.

Improves print quality, especially when printing thin walled objects.

The mount is designed for a 40mm fan with 4mm holes and a hole spacing of 32mm.

Consist of:

  • a fan mount,
  • a funnel to guide the air directly below the hotend nozzle
  • a fan grill to protect the fan

Without the funnel the fan will blow to much air against the hotend, so that it may fail to reach more than 205 °C, with the funnel it may still be necessary to raise the hotend temperature by 3-5°C. (I use 213°C for PLA).

A higher heatbed voltage may also be necessary. (I use 19 V for PLA)

I'm not entirely happy with the funnel geometry, comments/suggestions are appreciated.

Fan grill created with "Parametric fan grille": http://www.thingiverse.com/thing:11906 With parameters:
hole_spacing = 32; hole_size = 4.5; outer_size = 40; corner_cut_radius = 27; outer_circle_diameter = 38.20; inner_circle_diameter = 15; outer_thickness = 3; inner_thickness = 2; vane_count = 8; vane_width = 0.5; ring_count = 3; ring_width = 0.5;

Instructions

  1. Print fan mount
  2. Print fan funnel (optional, but highly recommended)
  3. Print fan grill (optional)
  4. Drill out holes with a 4mm drill, if necessary.
  5. Attach fan mount to the x carriage with existing M4x40mm screws (see photo).
  6. Attach fan funnel, fan and fan grill to the fan mount with 4x M4x25mm screws
  7. Increase hotend temperature by 3-5°C, if necessary.

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Thoughts to consider:

1.) the current design directs the flow onto the bottom half of the nozzle as well as the plastic being extruded. consider angling the top flat surface a bit lower to miss all but the very tip of the nozzle to minimize unwanted nozzle cooling.

2:) I recommend a smooth transition from a round fan exit hole to rectangular flow exit in the flow duct. This minimizes flow losses and gives you a nice laminar sheet flow at the point where plastic is being extruded.

3:) Avoid the notch in the exit, move the exit away from the nozzle and down. I think the exit in the flow duct can be 0.5 cm or 1 cm back from the tip since you should get a nice high velocity sheet flow.

4:0 Ideally the exit velocity is proportional to the inlet area / exit area times inlet velocity (subsonic incompressible flow). However, in a non-ideal world if the exit hole of the flow duct is too small compared to the inlet hole, you may get little air flow due to flow losses.

:)

p.s. I like the concept and approach.

don't know why there are 3 smiley faces instead of 1. must of hit the wrong keys.

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