Compact 4010 Duct System for the Ender 3

There is a newer version of this thing here: https://www.thingiverse.com/thing:4403017

I have reclassified this as WIP:

1. The tool heads are quite close to the rear pulleys which I need to change.
2. The Clamp for the V6 variants requires some modification.
3. I have now developed a 5015 fan version which requires incorporation.
4. Beta testing an Ender 5 5015 version.

Background

Although I really enjoy my Hydra Fan Duct design both my Ender 3 Pros have exclusively 4010 ducts with a Bowden system. I therefore thought they may be better suited with a more Compact Lightweight system that provides some expansion\versatility but keeps the base unit to a reasonable minimum.

Therefore this compact duct system which is based on a 3010 Hot End Fan(similar to the V6).

Only for 4010 fans and the Ender 3 the thing as a very minimal base duct whiuch can be expanded upon, adding weight with the various options. There is also options for tool change and a V6 version. The 3010 fan being smaller can be a little more noisy ( I have used rasonable quality ball bearing fans rather than hydrualic and therefore are quite good) but due to its size it sits above the heater block much closer to the heat sink and therefore hopefully is much more efficient than the stock 4010 cooling fan again like the V6. I have also included some work in progress BL Touch brackets for a starter for both the Stock & V6 versions. The system includes.

1.Stock & V6 base 4010 low profile ducts.

2.Tool Change options including Stock Direct Drive, BMG Direct Drive, Dual Gear Direct Drive and standard Bowden.

3.Easy front face height adjustment of fans up to 6mm.

4.Wire Management\cable Tidy options.

5.Clear viewing window of nozzle whilst printing.

Installation

1.I have also uploaded some basic installation guides for both the stock & the V6 versions. The guides only cover the basics to get started with the system. Please comment or message if you require further information. There are also uploaded images for BL Touch offsets and nozzle dimensions off the build plate.I have also uploaded a step file of the full system if anyone wants to create any derivatives.

2.You will need various M3 hex bolts ranging from 6mm long to 16 mm and some M3 Brass thermal inserts. The quantities of each will vary depending on which parts of the system you adopt. The inserts I used were:

https://www.amazon.co.uk/gp/product/B07PMZCP23/ref=ppx_yo_dt_b_asin_title_o07_s00?ie=UTF8&psc=1

3.The 3010 fans used: https://www.amazon.co.uk/gp/product/B07DB59XP8/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1

4.M3 Bolt set Used: https://www.amazon.co.uk/gp/product/B07JNDYL2B/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

5.All parts marked WIP in front of the file name have been printed but not yet installed. I di d have one previous comment that the BMG tool head flexed a little due to the small web, this can easily be increased but may interfere with the BMG aces hatch.

Printing

1.The majority of the parts print without support (the base ducts print upside down) except for the rear duct mounts which unfortunately require some support. I have included some sacrificial layers in some of the holes in the mounts which will need cleaning in addition to the supports.

2.The WM Upstand and Clips will require either a very slow print speed or a raft due to their small footprint.

3.It is suggested that parts be printed in the orientation uploaded.

4.I have included 2 sizes of Wire Management clip but there is also a rib on the inside of each clip which can be shaved if further cable space is required.

5.The ducts print without support on their backs but there is an integral support immediately below the lower front fixing boss which needs cleaning off prior to insertion of the 4010 fan (see uploaded image of duct).

6.Printed with White, Blue, Red & Black Amazon Basics PETG on an Ender 3 Pro, Ender 5 and my Hypercube.

Update:04_05_20 Uploaded V6 Clamp bracket which was missed off on the original upload.

Update:06\05\20 Revised and uploaded all 4010 ducts after undertaking some CFD testing. The air flow on the V1 ducts tended to focus to the rear of the nozzle. The V2 version corrects this issue.

-