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Downward Blower Duct for Replicator 2

by whpthomas, published

Downward Blower Duct for Replicator 2 by whpthomas Aug 29, 2013
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Summary

I have found when printing PLA, on some parts where even cooling is critical, the stock blower duct on the Replicator 2 is uneven. Favouring right to left movement, rather than left to right on the X axis. So I set about designing a new blower duct that directs air directly downwards for more even cooling. This design has gone through several iterations, but the latest one appears to do the trick.

As proof of concept I printed an enhanced version of the Make Magazine Torture Test using my redesigned blower duct and I think the results speak for themselves. There was a bit of excess stringing which obscures the results, but no dangling from the overhangs except the arch which had a modest amount.

UPDATE (Aug, 31, 2013) I added a small gusset to the design to stiffen it when printed in Nylon.

Instructions

I printed this in Nylon, which seems to handle the heat of being next to the nozzle. Cut off the tab support structure when its done - its only there to steady the duct while printing.

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Nice design.

I would say 2 things

  1. The duct hits the build plate clamps at the start of every print, where the bot lays down a bead on the front of the bed.
  2. Should recommend longer screws (M3x25 socket head cap screws)
Oct 16, 2014 - Modified Oct 16, 2014

Works great, I printed this out in black PLA, I have about 6hr on it with no issue. The plastic can get a little soft around the nozzle (as expected) but is still holding its shape just fine.

Minor overhang issue around where the blower fan connects, seems part of the bridge area is not level so for first 2 or 3 layers the it will bridge half way then start back to the same side. Although it did not effect the overall print too much.

Still going strong with the original PLA print I did, no issues with sagging/melting PLA. Looks as good as the day I installed it.

="thingiverse-755945a59ff256394631b079277ab8bc:disqus" href="http://disqus.com/thingiverse-755945a59ff256394631b079277ab8bc/whpthomas I'd printed one of these in PLA, it was decent BUT the issue was needing supports. I've slightly modified it for commercial printing (i.e. removed the little round bit at the back) and ordered this in Stainless Steel through Materialise for my machine! Having many problems with the factory blower of late

Where did you get the nylon?

Works fantastic! Thanks for another great upgrade to the Replicator 2.

Great design. I just finished printing in black PLA to see how the fit was and whether I could improve overhangs. I'm not expecting the PLA version to last very long but it should give me at least a few prints before it warps or droops.

I've just finished doing some testing. Overhangs are definitely improved over the stock duct and I'm happy to report that after 4 or so hours of printing the PLA version doesn't show any signs of melting even were it is very near the nozzle.

Does the PLA version still work OK or did you have to make a new one?

The fit is perfect by the way. This is a high quality part to be sure.

I am not sure if I am following you here but when my rep2 changes direction I can defenitively see a different pattern of the plastic. Has this something to do with the cooling?

I particularly notice it with overhangs, if they point left they have a rougher finish underneath then the ones that point right.

Why the blue tape between your carriage and bearings?

Just to make the fit extra snug.

once again, more great work!

One more, I presume you used a different base plate when printing nylon. What is your method, materials?

I have a Garolite (bakerlite) build plate specially for printing nylon. However others have reported success printing Nylon on painters tape using UHU glue http://youtu.be/YEPcc92OvZchttp://youtu.be/YEPcc92OvZc

Taulman provides some instructions for printing Nylon here http://www.thingiverse.com/thing:43634http://www.thingiverse.com/thi...

In my case, I print at 255c, 35% infill, 88mm/s extrusion speed and 270 micron layer height

High Strength Print Bed for 618 Nylon
by Taulman

I have some nylon but do not have that spiffy AL carriage (yet). As I am concerned about heat needed can you provide any guidance on what settings you used to print it? I do have my original blower duct in place at this time as I found some of your earlier efforts did not do well against the heat of the extruder when printing PLA, considering they were also PLA of course. Rock paper scissors problem. :)

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