E3D V6 improved fan adapter with modded Prusa MK3 Layer Cooling

thingiverse

### 2018-09-07 update: this is a big one that i have been working on for a few months now (on and off). a further delay was due to me switching from onshape to fusion 360 (due to onshape's change of terms). it has required many sacrificial prototypes and a few calculations and modeling and includes a new 30mm fan adapter and a new nozzle/layer fan outlet. * new 30mm fan clip (v3.50) - with significantly improved cooling of the lower part of the heatbreak, which result in smaller retractions, less heat-creep and faster times to ambient temp. the main improvements are: 1. a more optimized air-flow cone while still maintaining a low footprint and weight, while maintaining a strong structure. 2. an added venturi effect tunnel for better cooling of the heatbreak. tbh - i did not think the 30mm fan can create enough pressure/air movement for this to be effective, but i compared the same model - with and without the venturi and the results were very much improved (the complete comparison and results are below). 3. indexing/insert tabs were added - so the model can now both grip the heatsink (even without a screw), and it is always indexed at the same height. i can provide a model without them - if anyone is interested (or they can be removed from the provided step file). print settings: 0.2mm layer height, 0.4mm extrusion width, 15% infill, 4 perimeters. *!!! a left handed version will be provided as well over the next few days.* * a new nozzle/layer fan outlet (v3.5L3) - with an improved airflow which is divided to different height levels based on the direction. the front part is aimed higher - just below the exit of the hotend (you want the filament to cool *AFTER* it has bonded to the previous layer and not before), and the sides are a more dispersed jets aimed downwards and forwards. i recommend you print this in abs or pc/nylonx as it's longer outlets means it is exposed to more heat (i have printed without a silicone sock for testing purposes - but i do recommend using one). print settings: 0.12mm layer height, 0.49mm extrusion width, 15% infill, 4 perimeters. as mentioned before - i am making the move from onshape to fusion360, due to onshape's change of terms. so it might take me some time figuring out how to post the full models on fusion360 to a satisfactory degree. i still remain committed to making this fully open-source and it will be released (meanwhile - step files ARE available). scroll below if you are interested in the results of the cooling tests performed on the various models (i have only included the select few relevant, but you get the idea). ### 2018-06-08 update: i have added a 2 modified versions of the original layer cooling spout: * an easier to print version, with thickened walls and a few fillets and chamfers (marked as v3.4). * a lengthened version, which also features a lowered air flow for better cooling of the printed layers (marked as v3.41L). i recommend you print it in abs or some other high temp filament, since it is more directly exposed to heat, but the cooling performance is much improved. **print both versions with an extrusion width of 0.48mm for best results** also, due to a few requests i have added the following: * a left handed version * a 2mm lowered mount plate (for both right & left handed versions) * a bl-touch mount (i have not tested it, since i do not have a bl-touch, so feedback is welcomed) as always, all models include a .step file version for easy modification and were added and updated in the original onshape model (link below). ### original post: after encountering some problems with retractions on my e3d v6, and going through a rigorous testing process, i reached the conclusion that there is a problem with the standard cooling. if you attach it as intended - most of the airflow goes to the **upper** part of the heatsink which is not very practical, as it causes the transition zone to be higher than it could/should be. after designing a few fan holders and playing with the direction of the air - i settled on this design. it blows air to the lowest part of the heatsink and where the throat contacts the heatsink. this allows you to do shorter retracts (at least in my experience), and has eliminated any problems i was having with PLA related clogs due to the full metal path. i then wanted to try a few different layer cooling solutions. i started with the **excellent** fang by Lion4H (he was kind enough to supply me with a modded version for my earlier testing), you can check it out here - https://www.thingiverse.com/thing:2175956 and i highly recommend it for anyone trying a first layer cooling solution above all others. my only problem with it, was that it was too focused - meaning that printing an extreme small overhang at faster speeds caused the problematic areas to receive very little wind for a very short amount of time. so i went in search of other solutions (Diii, Ciii, prusa mk2, etc...) but none were giving me good results when printing at 100mm/s and above. when the prusa mk3 was released i immediately started testing with it's new cooler - and after a few modifications (for better airflow, and a stronger connection mainly) i settled on something i was happy with. being a big believer in opensource, i'm sharing the complete design via onshape - so you can basically do with it as you will (within the limitations of the license - which is very permissive). the fan holder was modeled in fusion360, and so was imported as a step file into the design. i hope to have the time to re-create the model in onshape and to then replace that current import. you can check it out here - https://cad.onshape.com/documents/fa9d2c92fc5fa4cfced6d32c/w/724d95ccf4edcc5b3c95359c/e/ec243d25a6057a7f96d04ce0 .step files are also provided for easier modifications, and if another file format (supported by onshape) is needed - please let me know. i also have an adapter plate for that fan holder that fits with the radial fang - if there's interest i can release that as well.