Better Blower Mk2

Under Construction... getting closer to being ready - just doing some testing...

One of my first projects, after getting a 3D printer, was to design & make an upgraded blower fan as the one that came with my printer was a bit puny. (See my Better Blower thing).

I'm still running that upgrade and it's doing a sterling job - indeed I'd go so far as to say the Anycubic Kossel Linear Plus is a great printer for the money and it's blower is really the only glaringly weak point. Still, I wondered if I could do better: -More Power! -Using more readily available parts -Easy to print and build -Suitable for most printers that rock a 40mm blower as standard.

...Hence the Mk2.

There are three versions of this blower; a simple version where space really is at a premium, a version using Venturi principles for added efficiency, and an actively blown Venturi version to get every last cfm. The three differ only with regard to their face plates and fans so: -The build process is the same for all three -If you change your mind you just need to print another face plate with associated fan

To an extent the parts can also be mix & matched: -The Simple fan will also work with the Venturi face plate -The Active fan will work with it's face plate or the simple one -The Venturi fan should only be used with its own face plate

Parts: -Print the required .stl files (The shell, a face plate, and associated fan) -A 60mm case fan, probably 12v (Other sizes may do)

Build: -Take your case fan and snap the fan mechanism out of it's housing, taking case not to break the wires. -Snap off the fan blades close to the plastic hub (don't remove!) -Remove most of the remaining plastic from the fan motor PCB. Best to do a bit at a time, being careful not to break the PCB or remove the wires. Don't remove the final part that attaches the PCB to the fan spindle - important!

-Take your printed fan and carefully press the motor's fan hub in to the recess. It should be a snug fit, but don't force it if too tight - trim more of the fan blade remains from the hub unil they do fit. -Pull apart again. -Now try to press-fit the fan motor's PCB in to the hole in the printed blower shell. Again it should be a snug fit, but minimal trimming of the shell may be required. -You should find all lines up nicely and the wires from the PCB will run down the gutter on the back of the printed shell.

-Press the fan back on to the motor's hub, it's time for a bit of eye-balling: You want to make sure the fan is free-running, and exactly square to it's new housing, with the motor PCB snug in it's hole... ...when you are sure all is lined-up apply super glue to the join between the motor PCB and the shell.

The motor is now installed.

-You will likely need to adjust the hight of the fan. While it should be a snug fit there should be some vertical play. The idea is to adjust things so there is a small even gap between the bottom of the fan and the shell. Also a similar gap between the fan and the cover plate once that is in place. -Happy? If the fan is really snug that's job done, but if you're concerned remove the fan one last time so you can add a bit more super glue to the hub and replace it (quickly) in exactly the position you were happy with. -At this point I would advise covering the exposed PCB at the back of your new blower with some tape to keep dust out of the spindle and reduce the risk of shorts.

All that's left to do is attach the face plate which should just clip in pace, (glue if you wish) and it's done.

You may need to change the plug on the wires of your new blower, but assuming you are replacing a 40mm blower the lower screw holes should line up for a strait swap.^

^The two lower screws should be enough for security but if not there are two options: -A bit of double-sided tape between the blower and it's mount should do -The blower shell does have the upper screw holes. Using them requires fitting the blower shell in place prior to fitting the fan and cover plate.

The good news is you should now have plenty of extra 'fuff' without much hassle.

Note: Chances are you have a bunch of unloved 60mm fans laying about to serve as donors. Some 5v, some 12v, of varying quality and power. Do pick the one most suitable for your application...

...for instance I built my blower using an old YS-Tech fan for quality and 'maximum power'. The down side is it not too quiet... ...not a biggie at the moment but once I've swapped out the motor drivers in my printer for quiet ones it could be.