Smart Effector 40mm Noctua fan duct by RGN01

Last crawled date: 3 years ago

I wanted to fit a Noctua 40mm fan to my Smart Effectors (one with an e3V6 and one with a Volcano) so came up with this.
One of my design objectives was to mechanically isolate the fan duct from the heatsink and the Z-probe capability so this mount fits onto the ball studs and only touches the PCB at these points.
There are four versions:
one for no accessories (both ball stud mounts are the same height)
one that allows various accessories to be added (through having one 'foot' thinner than the other), for example a blower fan for layers or a BerdAir type system. The accessories I have created are also included (note that I have not tested them all as they reflect various stages of development).
31 March 2018 update: I have now added a combined STL that has the duct for a 40mm fan and the BerdAir mount (40mm_Duct_with_BerdAir.stl)
2 April 2018 update: I have now added the 'EasyPrint' version. This is specifically intended to print feet down, with support on the bed only as it has sacrificial support in the STL (on the attached image it is in a blueish colour. This is 0.3mm thick and is easy to remove after printing using a scalpel and/or a screwdriver. This version also has 0.5mm greater bore on the cylindrical duct - intended to improve airflow slightly - and has recesses for M2.5 brass knurl nuts as it now uses M2.5 bolts to hold the fan. If extra long bolts are used for the lower pair then supports for the BerdAir tube can be attached to these points with an additional nut. If using BerdAir type cooling on a E3D V6 or Volcano this is the version I recommend, printed in PETG.
I use a Noctua 40 x 10mm fan but I understand at least one person is using one with a Noctua 40 x 20mm fan. I use the excellent Modelfixings servo screws to attach the 40 x 10mm fan http://www.modelfixings.co.uk/servo_screws.htm (not sure if they will be long enough for the 40 x 20mm fan).
The accessories include:
a ball stud nut mount for the third set of ball studs
a BerdAir type pipe holder
a 45° 40x20 blower fan mount
2x vertical 40x20 blower fan mount (different heights)
a vertical 40x10 blower fan mount
20190622 Update: Following a request I have added a copy of the source file in .RSDOC format. This is the basic version without printing supports and Berd-Air attachments.
20190623 Update: Added STEP version thanks fo @NexxCat
Other parts designed for my printers include:
http://www.thingiverse.com/thing:1959901 (GT2 belt clamp (Prusa Y-axis)
http://www.thingiverse.com/thing:1937232 (Arduino Mega and RAMPS v1.4 case)
http://www.thingiverse.com/thing:1905409 (Prusa i3 steel 10mm upgrade)
http://www.thingiverse.com/thing:1959974 (Prusa i3 Steel Y-axis motor mount)
http://www.thingiverse.com/thing:1991116 (Prusa i3 Steel X-carriage)
http://www.thingiverse.com/thing:1991117 (E3D Chimera / Cyclops mount)
http://www.thingiverse.com/thing:1994413 (dual E3D Thermocouple amplifier board - housing)
http://www.thingiverse.com/thing:1090661 (Belt driven Bowden extruder with 1:2.5 reduction)
http://www.thingiverse.com/thing:896676 (enclosure for SevenSwitch FET)
http://www.thingiverse.com/thing:922455 (8mm Z-axis leadscrew bearing holder)
http://www.thingiverse.com/thing:922309 (Z-axis NEMA 17 adjustable endstop bracket)
http://www.thingiverse.com/thing:899607 (cable chain)
https://www.thingiverse.com/thing:2334269 (LCD housing)
https://www.thingiverse.com/thing:2377049 (PSU cover)
https://www.thingiverse.com/thing:2395715 (Chimera & Zesty Nimble drive cable spacer)
https://www.thingiverse.com/thing:2407651 (Chimera Zesty Nimble X-axis set for i3 clone)
https://www.thingiverse.com/thing:2436869 (A dummy NEMA 17 motor to hold the 5mm shaft)
https://www.thingiverse.com/thing:2748978 (A Duet WiFi housing)
https://www.thingiverse.com/thing:2749324 (A layer fan for the Smart Effector)
https://www.thingiverse.com/thing:2814068 (A Sannce I21AG mount for 3D printers)
https://www.thingiverse.com/thing:2844881 (A cooling duct for a Noctua 40mm fan on a Duet Smart Effector)
https://www.thingiverse.com/thing:2846955 (A quiet BerdAir type pump mount)
https://www.thingiverse.com/thing:3333609 (A Raspberry Pi case with 40mm fan)
For avoidance of doubt, this item is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License. See http://creativecommons.org/licenses/by-nc-sa/4.0/ for more details.