Replicator 1 Cooling Fan

by jer, published

Replicator 1 Cooling Fan by jer Oct 20, 2012
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Replicator 1 Cooling Fan by jer is licensed under the GNU - GPL license.

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This is a work in progress, but has been printed and tested. This is a basic cooling fan attachment for a Replicator 1 with dual extrusion. It attaches under the extruder heatsinks and fans, replacing the fan spacers. It is designed to support a 40mm 24v cooling fan, similar to the stock replicator fans and blow air onto the extruding filament.

With the latest version, I've been getting very successful PLA prints.


I printed this with .10 layer height using sailfish firmware at 120mm/sec. Instead of using bolts (I didn't have the right size laying around) to secure the fan, I used some small plastic straps instead.

If you've previously downloaded, please update to the newest version. The latest version lowers the nozzel and focuses the airflow for much better cooling. I've also split the .stl files for easier printing. You'll now need to glue the two pieces together, but you can print without support material.

After installing the nozzle onto the carriage and before attching the cooling fan, I tape over the bolt holes on the inside of the nozzle. This will help keep the nozzle pressure up. I also started using a different fan, one with alot more static pressure.


Connect the cooling fan to the extra FET on the mightyboard. Using the latest Makerbot or Sailfish firmware (7.5 at the time of this writing) the fan can be controlled either by gcode or from the control menus.

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Hi, I'm resurrecting this thread. So I'm in the process of adding an active cooling fan to my makerbot replicator original and I'm using the makerbot software (V 3.10.0) and It has an option for a cooling fan speed at various points of the print and they are all at 50% but when the printer starts printing with those settings it still doesnt turn on the "extra" port on the mighty board. Do I need to use sailfish to run that port?

hi can you use a stander maker bot fan on the extra port

Sure, but I don't think you'll get optimum airflow with it. It should fit just fine mechanically.

So I'm doing something similar, can you be specific as to what setting/gcode is used to flip the extra fet on and off?

With the latest Makerbot/Sailfish firmware, it works using the standard gcodes. Your slicer software should give you a fan option. For example, in Skeinforge the cool tab lets you select fan options. When printing PLA, I use the option that turns the fan on at the beginning of the print, and turns it off when complete.

That's not what I asked, I'm looking for the actual gcode in question.

I don't know off the top of my head. You'll have to look it up. As I said, the tools I use do this automatically.

So I bought the fan, but looks like I can't do anything with it as I'll need to get extra wiring and a connector to the mainboard (?). And how did you route the wire from the fan to the mainboard? (you don't mention how to do this)

Your right, I had to extend the wire. I did so by soldering another wire to it and using shrink tubing the connection to ensure that no metal was exposed. The new fan wire routes through to the mainboard with all the others inside the cable wrap. I don't think you need a special connector though, as it should simply attach to the screw terminals on the mightyboard.

After I downloaded your file, I would say to print it in one piece is actually easier for me to use it. The extra printing time due to support is definitely worth it.

I have Sailfish 7.4 and the extra output does not work, you have a tip for me?

I'm currently using sailfish 7.4 without problems. This can happen for all sorts of reasons, from shorts/opens to software configuration. All I can suggest is for you to check to make sure its wired up properly (polarity and/or loose connections). You can also enable/disable the cooling fan manually from the menu to see if its a problem in your gcode.

Hi I printed the part, but didn't think how to power the fan. How would I go about doing that? thanks

I've connected the FAN to the extra 24V output on the mightyboard. Please make sure your using a compatible fan. I've linked the one I used in the comments. With the latest 7.0+ firmware (I use 7.1 sailfish), the fan works great, and is controlled by the cooling settings in skeinforge.

im on 5.2 firmware. I got two 12v fans the same ones as on the extruder . I was thinking to attach them both to the fan attachment on top of each other then wiring them to the same points as the other fans on the mightyboard. but yeah then I can't switch them off when using ABS which could be a problem. Is the spare point your talking about the one marked Miscelaneous/Extra? stupid question im sure.

Yeah, you can connect it to the extra. I believe the fans should be 24v, not 12 though. The stock fans didn't force enough air, please see my project description on a fan that works much better.