Upgrading my FLSUN to a 50mm Blower fan
When I upgraded my FLSUN Delta with a volcano kit from Aliexpress, I didn’t reinstall a part cooling fan. Mainly because I didn’t want to go back to the old 40mm fans I was previously using. I wanted to upgrade to a 50mm blower fan, and design a custom shroud for it.
You can find a 50mm blower fan on Aliexpress at this link.
Installing a blower onto the stock effector was pretty simple. Only one screw hole was available because of the design of my blower fan, so I opted to use a bit of epoxy for a stronger connection. Just the fan by itself worked quite well. It moved a lot of air towards the build plate, but it was pretty weak on freshly printed plastic. Since I’m using my delta to print at layers thicknesses up to 0.6mm now, I need stronger airflow around the tip of the nozzle.
I went looking around, and I found a circular nozzle design on thingiverse. It worked pretty well! I found that it sent some of the airflow upwards towards the hotend, though. Using the snap-fit connector as a base and Fusion 360 for designing, I made three different attachments. The first attempt worked, but it suffered from the same problem as the circular nozzle. I used two channels to direct air downwards at a slight angle, but far too much air was directed to the hotend.
On the second attempt, I separated the channels from each other and added some chamfers to help direct airflow. I left some space on the front for air to move forward, still thinking that it would help or something. I also doubled the height of the channels. It worked much better than the first attempt, and the airflow was impressive. I still wasn’t satisfied with the amount of air that was being directed around the nozzle.
Next, I moved the openings to the bottom of the nozzle. I used large chamfers to control the direction of airflow as much as possible. The resulting part is quite effective, and has no problems keeping up with my printing. There’s definitely a lot of room to improve, though. For starters, the outputs are different sizes so the airflow is going to be uneven. I tried to make one output larger to compensate for the fact that it has bends and is offset from the nozzle, but I wasn’t sure exactly how to do it. Still, parts are turning out much nicer with the new fan and attachment installed.
The files can be downloaded here, on thingiverse.