Fan Shroud for MicroSwiss Direct Drive Extruder on Ender 5 Plus by GiulianoM

Last crawled date: 3 years, 3 months ago

Summary
This is a fan shroud housing to fit the new MicroSwiss Direct Drive Extruder plate for the Ender 5 Plus.
It is designed to fit the MicroSwiss Direct Drive plate for the Ender 5 Plus, as shown in this model:
https://www.thingiverse.com/thing:4563691
You might be able to fit it on the narrower original MicroSwiss Direct Drive plate, but it's shaped differently and may cause problems.
Holds:
1 x 4010 Fan for Hotend Cooling
1 x 5015 Blower Fan for Parts Cooling
1 x BLTouch
1 x Dual-Port Parts Cooling Fan Duct
Hardware required:
2 x M3 10mm screws. for the screws in the left side of the plate.
3 x M3 6mm screws, for the screws in the right side of the plate.
2 x M4 20mm screw for the 5015 fan holes.
Both the fan shroud and parts cooling duct are complete.
The parts cooling duct is probably best printed out of ABS due to its higher temperature resistance.
I printed it out earlier in PETG which did work, but it warped from the heat over time.
The blue version in the pictures was the PETG, the red version is in ABS.
The Fan Shroud can be printed out of PLA or PETG or ABS.
To best fit the wires around the parts cooling duct, gently bend them up in a Z-fold fashion as shown in the last few pictures.
They should fit fine in between the blower fan and the parts cooling duct's arm.
BLTouch Probe Offset:
X -32.000 mm
Y -8.495 mm
The tip of the probe when not deployed is 3.381 mm above the nozzle, you will have to adjust and find the new Z offset yourself as it can vary.
NOTE ON THE FAN SHROUD
The center hole in the fan shroud has a thin 0
2mm bridge layer built in, to print without supports.
It is not a mistake!
Print it out and then cut out the hole with a knife.
Update 8/13/2020
Updated the Parts Cooling Duct to clear the locknut for the lower wheel.
Update 8/15/2020
Both parts have been updated with minor modifications, to fix the fit of the 5015 fan and the fit of the parts cooling duct into the fan.
Parts cooling duct now has a sturdier mounting flange, and matching reinforced holes to screw M3 screws into.
Update 8/20/2020, Part 1
Added pictures of the shroud in place, with the parts fan cooling duct installed.
Discovered that the parts cooling duct nozzles are right up against the heat block, making them a bit soft if the blower fan is off.
I tested with the hotend at 250C, and the PETG plastic around the nozzles was soft, but firmed up if the parts cooling blower fan was on.
I will adjust the angle and length of the ducts to compensate.
Also, the grub screw in the heatsink is blocked by the lower edge of the fan shroud.
I will also make adjustments there so the grub screw can be accessed from underneath.
Update 8/20/2020, Part 2
Both the shroud and the parts cooling duct parts have been updated.
Shroud now has a thicker wire retention tab, with slots for zip ties.
Parts cooling fan now has curved nozzles to clear the hot end block.
Update 8/20/2020, Part 3
Adjusted the height of the mounting flange on the Fan Shroud for the BLTouch, found it to be too high, causing the nozzle to touch the plate.
Increased the thickness by 3mm.
Update 8/21/2020
Shortened the height of the nozzles on the parts cooling duct by about 0.5mm, they were too tall and hit the Z-column rod brackets.
If you've already printed it, just carve off a little bit off the bottom of the nozzle to clear the bracket on the right side.
Update 8/29/2020
I updated the design of the Fan Shroud part so that it can be printed without supports!
The fan holes in the front now have a 0.2mm bridge to support the holes, just cut them out with a knife.
This requires good bridging capability, but otherwise should be fine.
Update 8/30/2020
Printing the fan shroud, I encountered an issue with the nozzle colliding with the part at 40mm height, or layer 201, where it goes to do the bridge layer across the top.
If you run into this, the setting that will fix this issue is called "Avoid crossing perimeters" in Print Settings, Layers and Perimiters in PrusaSlicer. Cura probably has something like it as well.
Also, under Infill, I recommend setting the Bridging Angle to be 180 so that the bridge goes horizontally across the X axis.
Otherwise the fan shroud printed great in PLA.