Buddy cover with fan and cable tidy

This replacement buddy board cover has a 4010 cooling fan and space to stash the Nextruder cables to make them look a bit neater.  There is ducting so the fan is not blocked by the cables, but admittedly the assembly is very fiddly.  

This model is designed in OpenSCAD with the BelfrySCAD library.  The main parts are press-fit together, so please calibrate the $slop variable for the library appropriately.  In my case I used CF-PETG (Tinmorry) which gives a high dimensional accuracy for a $slop value of 0.0.  It is unlikely that the fit will work if you just print the supplied models in a material with less dimensional accuracy (like normal PLA or PETG).

I wanted to use a 4020 fan but it resonated through the case and was just too loud.  The 4010 fan is comparatively silent, so it may be that the TPU fan-gasket part is not really needed.  I connected the fan to the spare 4-conductor ‘CLIK-MATE 15135’ connector on the main board labelled “+24v” and “gnd”, but be aware that on my XL (delivered in the UK in Jan. 2024), the labelling seems to be wrong - the bottom conductor is at +24V relative to the top conductor.  Sorry I did not get a photo to make this clear.

The PTFE tube for Nextruder 3 has to bend to get over the pocket for the cables; this is probably acceptable, but I chose to replace the tube with one 15cm longer (total 142cm) and pass it through the pocket as shown.  I used 4mm OD/3mm ID PTFE tubing for no filament binding, and this seems to match the original Prusa tubing.

Printed in CF-PETG except for the fan-gasket in TPU.

Use the latest development version of OpenSCAD to generate the .3mf file with all the parts at once.

BOM:

24V 4010 fan plus mounting screws (15mm or so).  Use thread lock of some sort on the nuts.

150 cm 4mm OD/3mm ID PTFE tube cut to size.

Clickmate 4 wire cable (300mm, used the other end for my enXLosure fan project).  This one from eBay, but the link will disappear.