HUSH! Quiet cooler for Ender 2 / 3 / 3V2 by Mikael70

Last crawled date: 3 years, 3 months ago

Design goals:
Quiet!
Better part cooler
Better hotend cooling
Low weight
Easy access to nozzle
Good visibility of nozzle with LED
Compact
Modular
No supports
Compatible with my Direct Drive solution EDLhttps://www.thingiverse.com/thing:4642537
Design choices hotend cooler:
50x50x15mm axial fan + resistor (quiet)
Pressure booster (axial fan has low pressure)
Adjust fan speed to same or better performance as original
Design choices part cooler (Claw 1):
Single radial fan 5015
Cooling from two directions
CFD calculations with Simscale. Note that the flow from a radial fan is not pedicular to the fan outlet (~20 degrees) and the flow is much higher on one side. Water test was needed to balance flow in right and left channel.
Result:
Noise reduced 11dB!
Same hotend cooling performance as original (measured inside heat brake)
5015 can be removed in 2 sec (hold in place with elastic band)
Part cooler is mounted with two M3x12 screws.
Everything can be removed with the two original screws
Parts:
Gelid 5 (50x50x15) fan (spec 12.9CFM/4000rpm@12v)
Resistor hotend fan 36ohm (I used 18+18ohm on positive led)
JST XH 2.5-2 connectors (for connecting fan to motherboard). Check polarity of connector.
Hair rubber band for 5015
Two screw M3x12 2 for part cooler
Two 5 mm LED + resistor 330 ohm
Radial fan 5015
Note on material:
I used both PLA and ABS. ABS is recommended.
Part cooler in PLA may deform if part cooler fan is turned off. Aluminum tape might help.
Note on axil fan:
Actual voltage at HE fan with 2x18ohm was 8.6v and speed 3630rpm
Pressure booster on HE increased airflow ~8%
Spire 50x50x15 4800rpm@12v did not work well. Rattling noise when mounted on x-axis (bearings can’t handle vibrations from X stepper motor)
Gelid 5 (50x50x15) worked fine. Start duty cycle ~20%
 
Note on radial fan:
NoName 5015 fan didn’t sound good at any PWM speed than 0% or 100% so I changed Marlin firmware to software PWM.
Note on pressure booster:
The wings is only one wall thick so make sure to use "Print Thin Walls" in Cura.
How to measure static pressure: https://www.thingiverse.com/thing:4401775
2020-12-10: Minor update
Reinforcement at coupling moved (for more space)
Ender-3 V2 support added (not tested)
2020-12-12 update:
EZABL 18mm mount (and 12mm with EZABLMini_18mmAdapter) added on request (not tested).
Distance from nozzle x=43 y=-2
BLTouch v3.1 mount added on request (not tested).
Distance from nozzle x= 24 y= 3
Distance heater block to Bltouch side 7.5mm (to close?)