[Remix] X2 Delta P Duct [V2R2.2] for the MK3S(+) [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 90° 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 the X-gantry's 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>Important Tip:&nbsp;</strong></p><p>Before you install this duct, please make a careful inspection of the inner duct walls and confirm that they are mostly free of <strong>stringing </strong>and <strong>overhang debris</strong>, both of which can have a significant impact on the duct's cooling performance. &nbsp;Take steps to remove them as best you can, i.e. use a small torch to quickly remove stringing, and (bent) needle nose tweezers to remove any stubborn remnants.</p><p><strong>Note:&nbsp;</strong></p><p>You can find the model for the mounting bracket at @teookie's posting <a href="https://www.printables.com/model/62523-delta-p-fan-duct-v2-r2-for-mk3s-extruder">here</a>. Installation instructions can also be found there. (Also attached both here for your convenience.)&nbsp;</p><p><strong>Updated Nov 6, 2022: Bear version added&nbsp;</strong></p><p><strong>*** This is experimental. &nbsp;I added per request from a few users. &nbsp;I don't have a Bear configuration printer so I cannot verify if this works. &nbsp;***</strong></p><p>If interested, please try and give me your feedback to improve it.</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 evenly between the left and right ducts!&nbsp;</strong></p><p><strong>Note: </strong>The max flow velocities in the CFD 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 24V 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 open them up – you'd want the final fit to be tight though.</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 and/or printers.</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 with some <strong>STARS </strong>to help others find it as well. &nbsp;</p><p>Also please post a make as I would enjoy seeing you get good use out of it - it would make my day! :-D</p><p><strong>Installation Instructions</strong> by @teookie, presented here only for your convenience:</p><p><strong>Note </strong>that these steps show @teookie's geometry (not my remixed X2 geometry)</p><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/f982e1c1-786c-4c7b-806e-fc2e2fdc3f75/delta-p1.jpg#%7B%22uuid%22%3A%22d9c575c6-776d-4908-a8bf-691e1db92e88%22%2C%22w%22%3A586%2C%22h%22%3A410%7D"></figure><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/e7f984a8-48e3-444a-93e5-954a867b3fd8/delta-p2.jpg#%7B%22uuid%22%3A%229b734312-7e24-4aac-ab8b-3eb966c47bf1%22%2C%22w%22%3A596%2C%22h%22%3A482%7D"></figure><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/3f405b88-ab45-45dd-9ce1-4869da91ed24/delta-p3.jpg#%7B%22uuid%22%3A%2207aad443-6de1-4465-b5df-8f346550c6cb%22%2C%22w%22%3A584%2C%22h%22%3A444%7D"></figure><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/802341e3-40a7-48d9-bb32-f7ae2401e5ba/delta-p4.jpg#%7B%22uuid%22%3A%22721c9e72-366e-4b05-b09b-093248206930%22%2C%22w%22%3A576%2C%22h%22%3A429%7D"></figure><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/575dbea7-47d9-46b8-9344-2af602b2171a/delta-p5.jpg#%7B%22uuid%22%3A%226d4d1b34-d23f-4559-9a32-4b0fd902ef44%22%2C%22w%22%3A561%2C%22h%22%3A360%7D"></figure><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/37cdc5d4-279c-4be0-aa0d-3d6c460e8a24/delta-p6.jpg#%7B%22uuid%22%3A%22299e1906-bebf-44d9-975e-41403191d05c%22%2C%22w%22%3A598%2C%22h%22%3A536%7D"></figure><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/b20562b9-b1f6-4902-9393-74d86651b6d0/delta-p7.jpg#%7B%22uuid%22%3A%22e4922503-fd4c-4673-b33f-62dea8a754ee%22%2C%22w%22%3A575%2C%22h%22%3A474%7D"></figure><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/3feef79a-c4ae-429b-8722-f795515f9d81/delta-p8.jpg#%7B%22uuid%22%3A%22b5ea1f00-16d8-47e6-af89-6b550b0bfcc2%22%2C%22w%22%3A607%2C%22h%22%3A385%7D"></figure><figure class="image"><img src="https://media.printables.com/media/prints/155387/rich_content/b60627d4-1ed9-41cf-8ecc-272a6292f7e2/delta-p9.jpg#%7B%22uuid%22%3A%2200c2d41d-7d6a-4fa6-854f-952860d9344b%22%2C%22w%22%3A570%2C%22h%22%3A613%7D"></figure><p>If you are still reading this, congratulations, you are serious about 3D printing!&nbsp;</p><p><strong>Happy printing!</strong></p>