Wanhao i3 v2.1 stock 40mm fan rear mounted duct

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##Warning! ###Resent Testing Showed A Major Flaw! >As I'Ve Mentioned In Description Below Using This Duct At 100% Fan May Cause Nozzle Temperature Drop By 5 Degrees. I'Ve Done Some Research And Found Out That This Is Most Likely An Indication That The Actual Temperature Drop Caused By The Cooling Flow Is Much Higher, So High In Fact That There Isn'T Enough Power To Fully Compensate (As A Result A 5 Degrees Drop Remains), Thus Printer Consumes Much More Power And __All Of It Goes Through A Single Plastic Power Connector__ On Melzi Board Inside Control Box. >I'Ve Been Printing In Pla, Abs, Petg At Nozzle Temperatures From 200 To 250 C And Bed Temp. From 60 To 100 C For Hours Over The Past Month (At Higher Temperatures The Drop Was Up To 15C) And As A Result One Day My Printer Began To Reboot Continuously Because Of __Partially Molten Plastic Power Connector__. I Removed The Molten Plastic And Soldered Power Wires Directly To Power Pins On The Board, So My Printer Works Fine Again. >I'Ll Try To Make Modifications To The Design To Correct This Flaw, In The Mean Time Adjust Fan% To __Ensure No Temperature Drop__ During Printing, Or Refrain From Using This Thing Until I Correct It! This Is A Rear Mounted Cooling Duct For Stock 40Mm Fan Of Wanhao Duplicator I3 V2.1 (To Be Screwed To One Of The Printing Head'S Lower Bearing Plastic Casing M4 Holes). It Is Designed To Be Attached To The Printing Head With A 20Mm M4 Screw With Conical Cross Head Shown On The Last Photo, While The Fan Is Attached To It With Stock M3 Screws. The Thread In The Holes For The Fan Print Well Enough With 0.2Mm Layer (Not Detailed, But Resulting Rough Surface Matches Well With Stock Screws). The Bottom Most Surface Of This Duct Is Designed To Be At Least 1Mm From The Print Bed At Minimum Z Position. I Also Designed Appropriate Supports For The Fins. Both Duct'S And Supports' Geometries Are Positioned To Be At Duplicator'S Print Bed Center (X100 Y100) So Manual Positioning Shouldn'T Be Required. Stock Wanhao Cooling Fan Configuration Is Known To Blow To The Right Of The Nozzle Instead Of Straight Beneath It And It Also Blocks The View Of The Print, So I Decided To Design A Rear Mounted Cooling Duct For The Stock Fan With Better Performance. This Design Is A Result Of Several Cfd Simulations, Aiming At Improving Aerodynamic Performance. Compared To The Stock Configuration This Design Shows Improved: - Flow (3.25 Cfm Instead Of 0.98 Cfm In Stock Configuration) Due To Straight Streamlined Channel With Only A Mild Constriction, Bigger Exit Cross Section Area, And Curved Fins On The Walls That Reduce Residual Swirl Of Air Exiting The Fan; - Flow Direction. I Managed To Straighten Significantly The Swirling Flow Of The Fan And Aim It Directly At A Small Area Right Under And Around The Nozzle (In Stock Configuration Computed Flow Deviated By ~34 Degrees To The Right From Straight Line And ~14 Degrees Towards The Build Plate Because Of Air Swirl) Without Causing Any Serious Temperature Drop Of The Nozzle During Printing; - The View. Now I Can Easily Visually Check The Printing Progress. It Should Be Noted That At 100% Fan While Printing First Layers Near The Base Plate Or Printing Vast Flat Solid Layers, Nozzle Temperature May Drop By 5 Degrees Because Of Flow Being Deflected From The Surface I Printed This Duct From Pla And Used It To Print With Pla And So Far It Didn'T Show Any Temperature Damage From The Print Bed (Heated Up To 70 Degrees) Or The Nozzle (Heated Up To 205 Degrees) Even With The Fan Turned Off. Hope This Thing Will Help You Improve Your Prints Quality, It Surely Was Interesting To Design It And See It Performing Just The Way I Wanted)

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