After using my X1CC for awhile, I realized that I didn't want to keep disconnecting the extruder fan assembly wire every time I needed to do maintenance, but I also didn't want to simply let it hang there by the single cable. There have been a few attempts at solving this issue by others, ones where the fan assembly cover hangs off the rods (which feels weird to me - I don't want anything touching the rods but the carriage bearings), and another where it just connects by one pair of magnets, which doesn't seem strong.

So I designed this. My first attempt had a few concerns, one of which was that it covered the PTFE tube in a way that stopped you from working on that part of the extruder. Also, because my original design wasn't symmetrical, it wouldn't work easily on the P1P, which swings the other way due to wire placement.

This design is symmetrical, and it has a much higher arc, it uses less material, and the magnets in the BOM are stronger and longer, for a much better fit.

I'm a big fan of intentional design, and thinking about how to keep supports out of the final print. I got most of the way there, although you'll likely want to print with supports on the “female" side of the connectors. The angle I used in the connector is a little steep, so in order to keep it at the right angle and avoid drooping, supports are probably your best bet. The magnet hole covers are “domes” so hopefully you won't need support to print those. (I didn't.)

Speaking of magnets, the BOM is $10, and you'll get a bunch of magnets to use in other projects as well:

https://www.amazon.com/dp/B075PMBBY3

Basically, went with 5mm (diameter) by 8mm (length) magnets, so they stick out of the holes a little, but also have lots of friction connection space inside the model.

If you find that the holes are a little too big, you can either use CA (Super Glue) to secure the magnets or, use negative hole compensation to shrink just the holes. If you find the holes are a little too small, use positive hole compensation for slightly larger holes. Each material has its own shrinkage factor, so you may need to dial this in. I've never had to use more than 0.2mm on either side for any of my designs/prints. Remember not to scale the piece, as this will likely mess with the connectors, but hole compensation is fine.

Printing with PLA, I find that the arc is very strong, in “Strength” mode at 50% infill. When I was removing the magnets from the test piece, I decided to test by twisting - it twisted with a LOT of force, but did not break. Feels like a solid design, although I might add 1mm or so to the arc to make it even stronger. We'll see how the feedback comes back.

Overall, I'm very happy with this design, and I hope folks use it and maybe get inspired to have other ideas for ways to improve the design in the future.

I love to hear your feedback! Any questions, comments, suggestions are very much welcome. I also love to see the final prints and makes of my designs, so please share those if you are able.

I've already had a few P1P folks print this design out, and it works well. Just flip the male and female sides, and it will hold the fan cover off to the left.