Ender-2 Quiet 50mm Hotend and part cooler

thingiverse

Design goals: Quiet! Better part cooler Same or slightly better hotend cooling Low weight Easy acess to nozzle Good visibility of nozzle Easy to remove part cooler Design choices: 50x50x15mm axial fans (radial fans is supposed to be noisy) Pressure boosters (axial fan has low pressure) Adjust fan speed to same or better performance as original Big opening for the part cooler to get enough air flow with axial fan. Result: Noise reduced 11dB! Same hotend cooling performace as orginal (measured at upper and lower hotend grub screw) Weight without part cooler reduced from 62g to 49g (-13g) Weight with part cooler increased from 62g to 49g+43g (+30g) Parts: Gelid 5 (50x50x15) fan 2pcs (spec 12.9CFM/4000rpm@12v) Resistor hotend 36ohm 1 pcs (I used 2x18ohm) JST XH 2.5-2 connectors 2 pcs (for connecting fans to motherboard) Note on voltage: PSU: 12.32v MB header HE: 11.48v MB header PC: 11.42v Note on material HC: PLA/ABS/PTG PC: (PLA)/ABS/PTG PC in PLA will deform if PC isn't cooled from the inside so PLA is ok if you only print in PLA. Actual voltage at HE fan with 2x18ohm was 8.6v and speed 3630rpm Pressure booster on HE increases airflow ~8% Pressure booster on PC increases airflow ~67% Note on fans: I dont think replacing the orginal HE fan with a NF-A4x10 FLX is a good idea. Original fan 40x40x10 7400rpm (12v) measured open air (old fan). NF-A4x10 FLX 4500rpm (12v) spec. FLX @4500rpm cant have the same air flow/pressure as the original fan Spire 50x50x15 4800rpm@12v did not work well. Rattling noise when mouted on x-axis (bearings can’t handle vibrations from X stepper motor) Strange sound when controlled with PWM as part cooler. Gelid 5 (50x50x15) worked fine. Start duty cycle ~20% Obs! Plus and minus on JST XH 2.5 for fan is oppsite compared to battery cables **Update:** One tiny screw and four hooks isn’t enough to hold the hotend cooler securely so I will change the design some time in the future. I still us it with some hot glue. The change is on my low priority list since no one else is using it.