Bowden Heatbreak 40mm Fan Clip Duct

thingiverse

I printed this for my "RepRap Champion J-head V6 Hotend" that I got on Amazon. The fan that I had was small and the clip did not fit the heatbreak. It is designed for a 22mm diameter, 26mm height heatbreak, and accommodates a 40mm fan (fastener holes are spaced 32mm on center). Please note that the holes are 3.8mm in diameter. This was intended for 4mm bolts, but I undersized the holes so that I could cleanly drill them once done printing. Print Settings Printer Brand: Prusa Printer: Prusa Steel Rafts: No Supports: No Resolution: 0.4 nozzle, 0.2 layer height Infill: 100% Notes: I used PLA, and the clip seems to be holding up after a putting on and taking off a couple of times, but I will upgrade to ABS if it breaks. Post-Printing I scraped the inside of the duct with a pocket knife and then sanded in order to remove the plastic strings from my printer head moving over the gap. How I Designed This This was designed using Fusion 360 using the following process: In the XY plane, create the block that attaches to the fan by extruding a square, subtracting the bolt holes (extruded circles), and filleting the corners. Create a 38mm circle on the fan side and a 34mm circle on the clip side of the block. Use the loft tool to loft one of these circles to the other. This subtracts the duct through the block portion. In the XZ or YZ plane, create a profile of the clip. This consists of a 22mm inner diameter and a 26mm outer diameter. Use an 18mm wide rectangle to approximate the location of the clip's hole. Symmetrically place 2mm diameter circles at the clip openings. Place a rectangle on the block side of the clip profile. This should be 26mm wide and extend to its tangent with the larger created in step 4, but be at least 10mm from the nearest side of the block. Use the trim tool to remove all excess portions of the profile for the clip. Be sure to leave the entire inner diameter of the clip clear so that it will fit over the heatbreak. Extrude the profile to 26mm. In the XY plane, create a rectangle at the height coincident to the widest point of the clip's inner diameter. Ensure that it is 22mm by 22mm and is centered over the clip. This allows 2mm thickness on each side. Extrude the rectangle created in step 9 through the clip, creating a clear duct towards the block. First, loft the outer rectangle of the clip to the outer circle of the rim on the block. Next, loft the inner rectangle of the clip to the inner circle of the block's rim. This will be subtracted from the shape, creating the middle section of duct. Your design is complete!