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High performance cooling assembly

by Gascat, published

High performance cooling assembly by Gascat Feb 4, 2017
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Summary

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:

Wanhao

Printer:

Wanhao Duplicator i3 V2

Rafts:

Doesn't Matter

Supports:

Yes

Resolution:

0.2 mm

Infill:

100%


Notes:

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.

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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.

Gascat,

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!!

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