Wanhao Duplicator 9 D9 Top Fan Blower upgrade - V12 by Bleugh

Last crawled date: 3 years, 1 month ago

Small Edit...
Seems that most D9's are using only 3 screws to hold the upper fan in place.
I've left 4 holes in the model though as it looks better!
My blower's been working fantastically for a few months now, and it's only my 'trial' PLA print!
There's a few files in here, Just print the one with the highest number! V12 as of typing this.
V12 should help fix some issues seen with holes offset slightly on the extruder
This replaces the top fan in the wanhao duplicator 9. The top fan is the heat break fan and doesn't seem quite strong enough for those 30+ hour prints...By replacing the existing fan with this blower, it should keep things cooler and prevent heat creep.
Uses standard cheapy 5015 radial fans / blowers like the one shown in the image
You need
3 x M3 x 12 Allen Key Bolts / screws (Re-use the original ones!)
1 x M3 x 25 Allen Key Bolt / Screw (to lock the blower in place)
I've made this so that you can re-use the 4 existing allen key screws.
Those are 4 x M3 x 12 - the front two are a snug fit - the holes are 5.5mm diameter. the rear two, taller holes, i've made the holes 6mm diameter, on my printer, it's snug, a little force is needed, but they'll go alright....if you really don't want to use force, just drill them a little, not all the way through to about 8mm from the bottom.
(see REV 4 pictures)
My printer has a 15.5 to 16.5mm clearance (yes, it's slightly 'diagonal!) behind the stepper motor to the X carriage so this print at 15mm thickness on the back part should jam in nicely.
if yours doesn't fit, you should be able to loosen the upwards facing screws holding the two large red parts of the extruder together, jam this in, then tighten them back
Happy to discuss any commercial use of the device
Thanks tohttps://www.thingiverse.com/thing:1576438
for the model of the blower that really helped to get the first run of this design right....
Things remaining
Investigate airflow optimisation
Revision History -
Rev 4 - Original Upload - Functional,works well but flimsy
Rev 6 - Uploaded - Improved supports for fan screw holder, Costmetic changes
Rev 7 - More minor changes, Vertical 'slot' moved forwards slightly to help alignment. - Screw holes for Fan mount changed to M3 x 25
Filled in area on the right hollowed out to assist with bed adhesion - the print seems to lift a little in the front right corner
Fan screw support bracket thickened to enable easier printing and better functionality
STL generally tidied up and aligned to give a perfect finish
Rev 8 - Tiny tweaks to cosmetics only.
Rev 9 - Adjustment to rear 'wall' so it's tapered to assist airflow
Rev 10 - Adjustments made to allow for Wanhao manufacturing variations.
Adjustment to screw holes and locations - I've made them bigger (from 6mm to 7.5mm) to give much more allowance for manufacturing variations from wanhao.
I've also reduced the length of the blower from front to back by 1mm to make fitting easier
Rev 11 - Cosmetic changes, alignment adjustments of the holes and increase of screw holes to 4mm to allow 1mm 'free play' for an M3
Slimmed down the walls by around 1/2mm on the rear, front and right hand side to make fitment easier
Rev12 - Fattened up the internal parts, especially at the tall back side as the walls were a bit thin when printed, should be at least two widths thick now!