I wanted to have less noisy fans for my Kossel XL Plus which also provide a more powerful part cooling.
Therefore I was thinking about a way to use a 40 mm fan for the cooling of my hotend and two 5015 radial blowers for part cooling. I did not want to reduce the printable area of the printer and therefore everything had to be tightly packed to the Smart Effector.
I found JimboRRs nice design of a fan mount but did not want to remove the self tapping nuts at the Smart Effector when changing a fan mount. Therefore I modified his design, so that it can be mounted on the self tapping nuts and be secured with a flat nut, which fits on the remaining thread below the mount.
My version of JimboRRs design additionally tilts the radial blowers by approximately six degrees around their axis of rotation to avoid coming in contact with the rods when at the border of the printbed. The pictures above show a previous version without this tilt.
To use all three sides of the Smart Effector I designed a mount for the 40 mm hotend fan which uses the same connection-system as the part cooling fans to mount it the same way on the third side of the Smart Effector. The part has a slot on top. This slot prevents a collision with one of the three screws holding the extruder on the Smart Effector. The mount of the 40 mm fan is designed to use threaded inserts for the screws holding the fan, as shown in one of the pictures.
The nozzle of the radial fans is very short since I wanted to prevent it from melting regardless of how the heating block is orientated towards the fans. Since the 40 mm fan has to go on the only side of the Smart Effector without any connectors on the bottom, there is only one way to mount this whole setup.
Two words of warning!
The combination of two 5015 radial blowers for part cooling is very powerful. If I go above 70% fan speed the 24V E3D V6 hotend is not able to hold its temperature any more. When dealing with high hotend temperatures I even have to go down to 55% fan speed, maybe because of the power supply giving less power to the hotend. This is not bad because the fans are less noisy when running at a lower speed. But you should be aware that printing with 100% fan speed is not possible. Maybe a different nozzle design cools the hotend less. I will try this out but feel free to also remix another version of the nozzle.
- The Smart Effector becomes heavier with this fan setup. Therefore in my printer the currentless holding torque of the motors cannot support this weight when the printer is turned off. I am still thinking of a way to hinge the Smart Effector before turning the printer off, so that I do not have to move it down manually preventing the Smart Effector coming down by its own and maybe crashing into the hotend. When I find a nice solution for this, I will upload it here.
EDIT June 10th:
The solution for this problem is here.
I hope this design is what you are searching for and you can use this parts for your printer.
EDIT May 26th:
I added version nine of the fan nozzle which has only very slightly changed compared to version eight. It should now blow less against the hotend nozzle.
Think3DPrint3D Kossel XL Plus
Since the parts are close to the hotend and printbed you should use something more temperature resistant than PLA for printing this. I used PETG. ABS could be even better.