Please post pictures if you've made one.
Update August 3rd, 2018
It's been 5 years since I uploaded this; it's long over due for a revisit. Over the course of this time, one of my hard drive had become defunct and I lost the original design file for it. so I had to redo it all from memory. I took this opportunity to implement some design improvements.
Rev 2 Design Changes:
Many makers had complained that the inlet opening was too big, so this time I've made it with a little velocity stack.
My initial totally non-scientific test shows that the new design exhibits much less turbulence and pressure leak around the inlet.
Since i had to do a neck for the inlet to make a velocity stack, I made the impeller more reminiscent of the compressor wheel in a turbo charger. Increased the thickness of the hub to increase grip on the motor shaft. Running the new fan on a single 18650 lipo cell at 4.2V full charge, it makes a whining noise and produces a nice powerful air jet at the outlet.
Designed a new motor mount. I only had the one motor on hand to play with, so that's what I designed it for. They're fairly standard; you can buy some like it at this link.. https://goo.gl/jyQ8GY
it's best to print this part with supports, that's why i've uploaded it separately from the other parts.
- Changed the bolt pattern a little bit and reduced the number of bolts required. A maker wanted me to make the bolt pattern square, but I'm just too stupid to figure out how to arrange them around this geometry so that it's both square and not protruding too far from the shell. i will however upload a drawing of the bolt pattern so makers can design their own motor mounts for different motors.
In addition to the printed parts, you'll need:
1 - 3-5V DC motor like these https://goo.gl/jyQ8GY
4 - M3 x 20 bolts
4 - M3 nuts
1 - M3 Washer
1 - Power supply of your choice to power the motor
- Print parts
- Ream center hole of impeller with drill bit to fit snugly onto your motor shaft. The size of drill bit you need will vary with the motor your choose. Mine had a 2mm shaft. We want this to be a press fit.
- Insert motor into motor mount
- Insert shaft of motor through the center hole on the fan housing.
- With the motor shaft through the housing, place M3 washer on the shaft and press fit the impeller onto the shaft.
- Place cover on top of the housing and insert M3 bolts through the bolt holes.
- Fasten the cover, housing, and motor mount together with M3 nuts.
- Ensure your power source is off, connect your power supply to the motor.
CAUTION! Wear eye protection before you power up the motor.
Power on the motor and check rotation of the fan. It should spin counter clock wise. If direction of rotation is wrong, reverse polarity of your power connection.