High performance cooling assembly

by Gascat, published

High performance cooling assembly by Gascat Feb 4, 2017
9 Share
Download All Files

Thing Apps Enabled

Order This Printed View All Apps



Liked By

View All

Give a Shout Out

If you print this Thing and display it in public proudly give attribution by printing and displaying this tag.

Print Thing Tag

Thing Statistics

7585Views 1462Downloads Found in 3D Printer Parts


This is a helix fan duct for a 40mm fan with a blower, designed to redirect, shape and straighten fan's flow with maximum efficiency.

It is designed to be attached to Wanhao i3 v2.1 printing head with 2x 20mm M4 screws with conical cross heads, while the assembly itself is held together with stock M3 screws.
All threads in the holes print well enough with 0.2mm layer and match stock M3 screws.
The bottom most surface of this duct is designed to be at least 2mm from the print bed at minimum Z position.
I also designed appropriate supports, included in the model.

This is an evolution of my previous design with an addition of helix duct inspired by DaveGun's Vortex Fan Shroud. Like my previous design this one is a product of several CFD simulations.

The assembly consists of 3 parts:

  • helix duct with a 40x15mm rectangular exit
  • positioning frame
  • blower duct

I designed it this way to make it possible to switch blowers without having to print the whole thing and also to make it possible to use this efficient helix duct on any printer or in any other application that requires air flow.

I've also included models of 2mm thick dampening inserts to be made from flexible material to reduce noise and vibrations from the fan.

Compared with my previous design this assembly provides even more flow (up to 4.3 CFM which is quite close to theoretical maximum of ~5.5CFM for a 40mm fan) and has much less adverse effect on the nozzle temperature level. It is designed to provide cooling for 2 zones - main flow goes around the nozzle and a limited amount goes directly beneath the nozzle through a separate channel, this allows to maintain high flow rate in general and provide cooling of just extruded material without causing too much temperature drop of the nozzle. I've also included blower version without a small channel to further limit nozzle temperature drop in case you don't need to print any severe overhangs or small parts. 4x 1,5mm holes provide cooling flow to prolong blower life under high temperatures (I printed it from PLA and used it to print at nozzle temperatures as high as 245-250C and it survived the print without noticeable damage).

Print Settings

Printer Brand:




Doesn't Matter




0.2 mm




0.4mm extrusion width;

max. printing speed 25 mm/s;

Used custom supports no other supports required;

Printed from PLA
235C nozzle, 70C bed and 0% fan at layer 1;
235C nozzle, 60C bed and 100% fan for the rest of the print.

dampening insert were printed from Ninjaflex at the same settings except for 150% extrusion rate and 20 mm/s max speed.

More from 3D Printer Parts

view more

All Apps

Auto-magically prepare your 3D models for 3D printing. A cloud based 3D models Preparing and Healing solution for 3D Printing, MakePrintable provides features for model repairing, wall thickness...

App Info Launch App

Kiri:Moto is an integrated cloud-based slicer and tool-path generator for 3D Printing, CAM / CNC and Laser cutting. *** 3D printing mode provides model slicing and GCode output using built-in...

App Info Launch App
KiriMoto Thing App

With 3D Slash, you can edit 3d models like a stonecutter. A unique interface: as fun as a building game! The perfect tool for non-designers and children to create in 3D.

App Info Launch App

Print through a distributed network of 3D printing enthusiasts from across the US, at a fraction of the cost of the competitors. We want to change the world for the better through technology, an...

App Info Launch App

Quickly Scale, Mirror or Cut your 3D Models

App Info Launch App

Treatstock is an online platform that offers decentralized manufacturing services such as 3D printing and CNC machining for business-to-business and business-to-consumer sales all over the world. W...

App Info Launch App

3D print your favourite design with NinjaPrototype, a professional 3D manufacture with consistent quality and speed.

App Info Launch App

Did you print the flexible material using the nozzle in the photos, and if so, what was the material filament you used?

Any chance of getting the helix model file so that it can be scaled up for larger fan sizes?


This looks awesome. I'll print it as soon as my Z extensions are finished. What's that doohickey on your extruder heatsink, though?

Hey, is there a chance that you can do a new version your awesome Mod that is more optimized for other fans like the an Noctua NF-A4x20 (40x40x20mm).
I think it manly would require the the Helix channel to go further into the middle without the hole.

This great mod optimized for the best 40mm fan would propably be an alternative to even the pricier high RPM (5000-6000) radial fans. And it would be way more quiet!

holy shit this is by far the best fan duct i used with the stock fan! ups to you my friend!

Can you tell me what the bolt dimensions are center to center for the fan?

Printed and installed with gaskits reduced to 1.5mm. Massive improvement over stock cooling.
Thank you for sharing this design.

any chance we could get a slight mod version with a 45deg sweep from the mount away from the X-axis stepper motor? My Delta fan hits the stepper when zeroing the X axis.

Holy Cow. I upgraded to this with the stock fan because I didn't want to spend money on a blower. It works incredible and I immediately saw the difference when printing small parts in both detail and speed. THANK YOU SO MUCH

Any chance of a mounting bracket so this works on the wanhao i3 plus?

Sorry, but I don't have i3 plus, so I don't know it's configuration and dimentions.

This is by far the BEST cooler design utilizing the stock 40mm fan. Absolutely no perceived fan back pressure that I can tell. Some solid design work went into this setup. I'm actually afraid of parts being BLOWN off my bed with this thing.


What's that cooler hooked up to your Extruder fan? It also looks sweet - do you mind sharing it's source?

It is a previous iteration of the helix duct. It performs less efficiently and has different mounting holes arrangement. Since I had it printed anyway, I thought I should use it somehow, so I printed an adapter to mount it on extruder cooling block. I didn't notice any significant impact on extruder cooling though.

I LOVE a design that has some CFD behind it!

I don't have any Flex filament, is it okay if I use this design without the 2mm spacers, or should I still use the spacers with regular material?

Spacers are optional, added just to lower the noise, since my stock 40mm fan became quite noisy after months of use. And they served as a first test of printing flexible filament for me)

will the distance work if no spacer used? any chnace of a design for I3 plus & Coccon create touch? or will this version work with those printers

NOICE!! Your right, even better than the first one, which I like alot already!

Very nice, well done!!