Remix Delta P Duct [V2R2] for the MK3S(+) - X2 Duct [New Flow Splitter]

prusaprinters

<p>Thanks to the awesome Delta P duct design by @teookie, I saw a significant increase in air cooling flow, so I did a remix and added 2x LEDs to let me see the extruder.</p><p><strong>That remix is here:</strong> <a href="https://www.prusaprinters.org/prints/133276-delta-p-for-mk3s-with-led">https://www.prusaprinters.org/prints/133276-delta-p-for-mk3s-with-led</a></p><p>However with more usage, I noticed that the left duct did a better job cooling (stronger flow) than the right duct. &nbsp;I tried to study it using a CFD tool to simulate it but the model kept throwing errors, so I ran a “real world” test instead to validate my observation by having it blow into a small container of water. &nbsp;The pattern of the disturbed water surface would indicate biased or centered flow.&nbsp;</p><p>In the pictures attached, it shows the flow to be left-biased, side-by-side to the same test for the X2 that shows a more balanced flow.</p><p><strong>The X2 has the mods from my previous remix plus two others:</strong></p><ol><li>Rotated flow splitter by 90deg to help balance flow for left/right ducts - see rationale below.</li><li>Added a location for a 3rd LED looking head-on at the extruder - more light is better since the extruder is always shrouded in shadow.</li></ol><p><strong>Why did this work better?</strong></p><p>Since blower fans produce an uneven flow profile (faster velocity further from the fan axis), splitting the ducts evenly similar to what @teookie did would bias the flow to the left duct. However, &nbsp;@teookie tried to compensate for this by making the duct inlet on the right about 20% larger than the left. &nbsp;This helped, but apparently it was not enough. &nbsp;</p><p>Since I rotated the split for the duct 90deg (and split the left/right evenly) it directed the same amount of air to both left/right ducts.</p><p><strong>Updated Apr 4, 2022: &nbsp;CFD Validation</strong></p><p>I was finally able to run a computational fluid dynamic simulation to further study the flow.</p><p>The results seem to further validate physical observation. &nbsp;See pictures attached.</p><p><strong>Both flow volume and flow velocity appear to split evening between the left and right ducts!&nbsp;</strong></p><p><strong>Note: </strong>The max flow velocities are a bit artificial, since I just used a simple 4.4CFM as volumetric flow input. &nbsp;The main point is that the flows are split evenly. &nbsp;</p><p>I also found vortices forming at the duct outlet (flow going back into the duct at the exit), which will be a point for further optimization in the future (see pic).</p><p><strong>Animation of the X2 Duct Flow:</strong></p><figure class="media"><oembed url="https://youtu.be/B_wCQEGBSB8"></oembed></figure><p>&nbsp;</p><p><strong>Updated Apr 2, 2022:&nbsp;</strong></p><p>For those interested, the LEDs I used:&nbsp;</p><p><a href="https://smile.amazon.com/gp/product/B07VD1KRDW/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&amp;th=1">https://smile.amazon.com/gp/product/B07VD1KRDW/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&amp;th=1</a></p><p>I made the holes for the LEDs a bit tight so you can use tweezers to push them in for a tight fit. &nbsp;If they are too tight, you can use a 3mm drill bit to clean them up.</p><p>Wiring connector used: this provides quick disconnect for when/if you want to change the LEDs or do other experimentation.</p><p><a href="https://smile.amazon.com/gp/product/B083HWJ3P7/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&amp;psc=1">https://smile.amazon.com/gp/product/B083HWJ3P7/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&amp;psc=1</a></p><p><strong>Updated Mar 31, 2022:</strong> Uploaded STEP files of both versions per request to be modified to fit other mounting configurations.</p><p><strong>Updated Mar 27, 2022: </strong>By popular request…For those of you who prefer <i><strong>not </strong></i>to see the nozzle (joking):</p><p><strong>Added a version without the 3x LED features:</strong></p><ol><li>Backed out all the changes related to the LEDs</li><li>Kept the enlarged square nut pocket</li><li>Kept the changes to increase the view port size</li></ol><p>If you download the model or add to your collection, please click the <strong>LIKE </strong>button and rate the print to help others find it as well. &nbsp;Also please post a make as I would enjoy seeing you get good use out of it. :-)</p><p>Thanks and happy printing!</p>