Fan Duct, MendelMax 2.0

by JohnSL, published

Fan Duct, MendelMax 2.0 by JohnSL Jan 1, 2014
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I've been on a quest to improve the print quality on my MendelMax 2.0 printer. Watching a Replicator 2, I've noticed the fan makes a huge difference. I had been using two fans angled toward the top, using these mounts: http://www.thingiverse.com/thing:139952. You can see the latest version of this mount on the right side of the photo.

In an effort to improve the cooling airflow, I created this fan duct, which screws onto the carriage. This fan duct is thicker than many you'll find, but does a much better job. Here's why. The fan supplied by Makers Tool Works for the MendelMax 2.0 is good at moving air, but it can't pressurize the air much. So if the output vents are too small, most of the air flows back out of the fan on the outside of the blades rather than flowing across the part you're trying to cool. Using larger vents allows more air to flow around the part.

With this duct I've gotten the best print quality so far with my printer. Bridging works much better, and I get less sag on overhangs.

The last photo shows an example of before and after switching to using the fan duct. The light blue part is without the fan duct, while the dark blue part on the right is with this fan duct. You can see how much of a difference it makes. Both of these parts were printed from exactly the same g-code file.

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Where can I find the actual extrude mount?

Any chance you can make a Replicator 2 version? The current replicator 2x fans are terrible. I don't know who designed them but they clearly didn't understand material properties, heat dynamics or anything coherent, in science. Its anemic, only cools one side of the print because of the square heat block, which makes drastic differences on the opposite side (rear) especially on inner shells, bridges and overhangs. Its also far too close to the nozzle and melts away slowly above 230, and it's made from ABS which was a horrible idea for their design. It also cools the heater block, especially on slow filaments like Tglase and makes it 8-10c colder than your setting, it causes the PID auto tune in the firmware to go nuts. Great for LaywooD3 temperature wood grain scripts but that's pretty much it. And you can't even print LaywooD3 on a .4MM without major problems. I wasted 2 coils (0.5 pounds worth) testing and I finally got settings to work without problem, and it was a 100% infill print. I have the settings saved in a bundle CFG. If you want them, let me kknow, ill send it.
BTW, Im seeing some fan ducts that have water channels in the shell, with inlet and outlet ports designed for a tiny water pump and rubber hoses. Perhaps we can trade some models or settings sheets as a barter system. I love your design and would love it even more if it would fit my Replicator 2 duel nozzle. Perhaps we can trade some settings sheets ffor the trouble? I spend all day testing and taking notes in the lab and and have 11 years in the engineering and design field. Its my job at the moment to work out different settings for different printers. I'm sure I have what you need!

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Made one a few months back. Sorry no photo. Did not work as well as I would have liked, mainly I think because it didn't fit around my extruder head properly and melted onto it. I'm trying your latest design this week to see if it'll fix my Mendelmax 2.0 issues with overhangs curling and getting loopy.

Is it just me having problem with this fan duct being too effective?
I have to turn down the fan speed to about 50% to be able to keep the temperature of the hot end at 195°C.