Hero Me Gen5 - 5020 AXIAL Fan Dual Duct Remix on Ender 3 V2

Hero Me Gen5 - 5020 AXIAL Fan Dual Duct Remix on Ender 3 V2

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I had some spare rather quiet Axial 5020 fans around and I just bought my Ender 3 V2 and learned enough CAD to be dangerous. The fit is pretty tight but it works and although the length does change the center of gravity with the v-slot wheels, I don't notice any more movement than before or after mounting the direct drive kit from Micro Swiss. Update 9/18/20: I don't have an updated build yet but am working on it! Currently playing with firmware things so give me a few days. I've realized the failure/rattiling is a two-headed problem. The z-axis bracket (to which the x-axis is bolted on my ender 3 v2) has some y-axis directional wobble. That means (for me) >80mm/s printing, I get some wobble, which means the nozzle scrapes ever so slightly. Because I printed at an angle, the 5020 sits on a stepped/rough surface and once again because of the two bolts... the fan (not the fan housing!) bounces. I did temporarily solve this by adding a Z-hop into the mix, but at 100+mm/s... i get a really nasty noise as you'd imagine. So needless to say, I'll redesign a few parts and get back to y'all. Thank you for your patience. Oh and you shouldn't need the brackets once I get this done. WIll update. Update 9/8/20: When I was printing at high speeds (100+mm/s), I started to hear this rattle and assumed it was the fan housing but actually it's the fan 5020 axial fan that's now horizontal. There's nothing holding it down. I added a few braces to see if I can't get rid of it but we'll see. They are a tight squeeze even with PLA and require you bumping up 2 sizes on the M3 length but wanted to keep the connections strong enough. As a reminder, the M3 nuts do not fit in the opening I carved out, I can make them bigger or get rid of them but really it doesn't matter. The two furthest from the hotend work if you bolt them like in my photos. The real issue is over tightening the "thinner" bolt to the Hero Housing. That is printed so weakly that I need to revise it. It works but on my two prints of this it's cracked. Oh and I didn't try it with ironing but figure it could look nicer. Sand a bit with a file and you'll clean it up easily. That print was also using Bowden over my new Microswiss DD install. May try a fresh cleanup but we'll see. You also are generating some blow back/back pressure from the 5020. Not ideal but I figured it was way oversized anyway. I tried to design around it but there just isn't enough surface area down below to create large enough openings. I can run it at 60-70% and still get great prints and be much quieter than anything else I've tried The 5020 Axial fan will block the lower part of the 4010 but because they are both pushing in... it didn't matter much to me. Also, the exhausts do need to be carefully adjusted for height - They are taller than the standard nozzles that I have but I print with a silicon sock so figured it would be alright and they blow on the sock a bit. Supports: At least strategically to touch baseplate because of the curved paths. Also if your cooling is not good to begin with, I'd recommend some internal supports because you get a bit of warping but some sanding took care of it and it didn't impact the structure or dimension appreciably. Bed Adhesion: I used a Brim because of how I minimized supports but i'ts up to you. Cleanup: The print quality needs to be improved a bit (I wanted fast, easy and strong) and the sizing on the M3 bolts are a bit off (but you only need two for each fan anyway - the 4010 on the Hero5 base and the 5020 Axial on the addition. I played with the orientation a few times on this one and a couple other prints. I think printing flat would give you a nicer looking one but I'm fine with the function at this point. You will have to do some sanding/filing. I'm leaning it a bit rough but just note.

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