Phrozen Sonic Mighty 8K/12K riser/lid spacer and PTC heater frame

This is a mod for the Phrozen Sonic Mighty 8K/12K. It is a lid spacer/riser and frame for a PTC heater and W2310 temperature controller. The spacer is used so that there is no drilling/cutting of the cover and base for cabling and attaching the PTC unit. It can be printed on a smaller printer such as an ender 3.

Parts

Printed Components

Riser

3x frame corner (print with supports)

1x frame back left for heater (print with supports)

There are 2 versions, v2 has an additional 3mm in the x and y in case the originals are a too tight fit.

Heater Housing

1x heater base

1x heater 1 (print with supports and optional brim)

1x heater 2 (print with supports and optional brim)

Purchased Components

1x w2310 temp controller (12V)

1x PTC fan heater (70-150W 12V)

12-14 AWG cabling to handle the high current

2x Anderson connectors recommended for easy and safe connections

1x C14 with rocker switch and fuse

1x 20A inline automotive fuse

200+ Watt PSU - I went with a Mean Well 320W

Assortment of crimped terminals for connecting to the PSU, C14 and temp controller 

Optional 2x 300mm x 300mm insulation sheets https://amzn.asia/d/fNmQlQC

Material

Do not print this in PLA since it is for a heater, PETG or something more heat resistant is recommended.

Print Settings

0.4mm nozzle

0.2mm layer

0.5mm line width

3 walls

30%-100% infill

Assembly

1. Insert the heater base into the frame back left corner for the heater. Insert the side with the 2 pegs/inserts first at an angle from the bottom so that the side with the single peg (left side)  is slightly lower than the frame. Bend the left frame part just enough so you can level the heater base and snap in the left insert.
2. Assemble the 3 frame corners by snapping in each to the next.
3. Glue heater 1 and heater 2 together.
4. Insert the W2310 temp controller into the heater housing bottom part and make sure it snaps in place.
5. Insert the PTC heater into the top of the heater housing with the fan side facing the ground. Spot glue it in place if needed.
6. Wire up the temp controller, heater and PSU.
7. Glue the heater housing onto the heater base guides.
8. Position the cover upside down and stick the first 300mm x 300mm insulation sheet to the inside of the top.
9. Cut the remaining sheet of insulation in half.
10. Cut about 8cm off the longer side of the insulation sheet halves.
11. Stick the two halves flush in the corner and with the first sheet relative to where the heater is, this will stop the cover from getting hot and distribute/reflect the heat better and use less energy as well as reach target temperatures faster.

Credits

The PTC heater housing was inspired by https://www.thingiverse.com/thing:4727762