Tenlog TL-D3 Pro (Dual) 5015 Fan Mod for Stock Metal Shroud by Buriaku

Last crawled date: 2 years, 10 months ago

This is a modification for the stock metal shroud of the Tenlog TL-D3 Pro to use two (or one) 5015 fans per extruder. Air is sent to the back and front of the nozzle and distributed quite evenly. Airflow was examined using fluid simulation (Simscale) and water tests. For assembly, the metal shroud needs to be modified by removing the part sitting under the cooling fan by breaking or sawing it off.
The fans I used are from Winsinn.
Original Inventor files and exported STEP files of the whole assembly are provided.
Last two photos are printing examples of the "cooling fan torture test" by TeachingTech.
The single 5015 fanduct design was also used in the "Tenlog TL-D3 BMG Extruder V2" by andrewseago.
Printing:
Print with supports on build plate and the flattest part laying on the build plate (side for fanholder, bottom for fanduct). Check, that there is no support inside the fanducts before printing. I used 0.2mm layer heights with 0.3mm initial layer height. Inner divider walls are 0.84mm, which is the recommended width in PrusaSlicer for two walls at 0.45mm outlines, so check whether there are actually two walls.
Assembly:
Remove the metal shroud, disconnect the fans from the board and unscrew both fans before modifying.
The fanduct parts go on the inside and the fanholder parts go on the outside of the shroud joined through the air intake hole of the original part cooling fan. No holes need to be bored into the shroud for assembly, but the metal "flap" sitting under the heatsink fan needs to be removed by breaking it off (flexing back and forth with pliers until the metal yields) or sawed off (after bending it down). To prevent injury, remove any sharp edges with a file after removal. The inside and outside parts are joined using two screws, one through the side hole of the shroud and one through the long slit on the front of the shroud. Two longer screws are used to fix the fans to the fanholder. All screw holes are designed for M3 screws.
If using two fans, they need to be connected in parallel. Search for examples, if unsure what that means. On the blue/yellow cable of the original Tenlog fan, blue is negative (black) and yellow is positive (red).