Solder Fume Extractor with USB PD, compatible with Ryobi Batteries

Building off the ideas seen in other solder fume extractors, this is my version of the Solder Fume Extractor, attempting to bring the best in portability for soldering:

• fume mitigation with the widely-available Weller WSA350F Carbon Filter
• USB PD to power soldering irons such as the TS80P/TS101/Pinecil
• cordless and rechargeable power supply using the widely-available Ryobi ONE+ 18v battery packs
• voltage conversion to power a typical 140mm PC fan
• the Ryobi battery serves double-duty, providing a stabilizing mass as the base of the fan
• a large hinge allows for tilting the fan for optimal positioning
• the filter enclosure is able to be easily opened, allowing for easy replacement of the carbon filter when needed
• a hexagon grid pattern is used for style and functionality as the mesh pattern, the small hexagons are intended to keep tiny fingers safe

Materials needed:

Optional Materials/Tools

Printing:

Each component has been designed with an ideal print surface in mind, and these components are positioned appropriately in each of the 3mf files.

No print supports are needed except for the Ryobi Mount. The larger piece should be printed with supports enabled. The supports are needed for clip interface with the Ryobi battery and can be removed using a 90° pick.

PLA should be fine. I designed and tested each of the parts at 0.15mm layer height using a 0.4mm nozzle.

Assembly

Preparation

Set the heat-set inserts into the models as follows:

• The Ryobi battery mount needs 4 placed into the bottom face of the upper component.
• The Filter Housing Bottom Grid uses 4: 2 in the top and 2 in the bottom outer sides. These are used to secure the Filter Housing Outer. and allow for swapping the carbon filter.
• The Control Panel uses 2 inserts, 1 on each side of the mounting positions for the USB PD board.
• The Electronics Enclosure uses 9 inserts: 4 in the front, used to attach the Control Panel, and 5 on the bottom for Ryobi Mount.

Electronics Assemblies

Using the above diagram as a guide, solder and finish the wiring using heat shrink tubing and XT30 connectors as needed.

When using the XT30 connectors, pay attention to the polarity. Note that the flat side is marked “+” to indicate the positive side.

Do not connect the fan yet. The buck converter needs to first be calibrated to the correct output voltage.

To prepare the fan connection, cut off the fan connector, leaving most of the fan wire intact. Then strip the black fan wire (GND) and the yellow wire (+12V).  If you are using a fan with a 3-pin connector, check the documentation for the fan to verify which wire is +12V vs GND. Noctua provides a diagram for the pinouts.

The Ryobi battery connector needs a pair of red and black wires, about 15-20cm in length, soldered to cell leaf springs, then mate the ends of those wires to a female XT30 connector, finished with heat shrink tubing.

Slide the cell leaf springs into the slots for the Ryobi battery connector housing, paying attention to match red (+20V) to + and black (GND) to -.

Test and Calibrate Electronics

The buck converter needs to be adjusted and set to output 12V before connecting the fan to the rest of the components. To do this:

1. Join the XT30 connectors so that the battery connector housing is connected to the electronics assembly.
2. Place the battery connector housing onto a Ryobi ONE+ 18V battery, and push down gently so that the leaf springs make contact with the battery terminals.
3. Verify voltage output by probing the leaf springs using a multimeter. It should read about 20V DC.
4. Connect a multimeter to the “OUT+” and “OUT-” side of the buck converter and monitor the voltage while adjusting the screw potentiometer on the buck converter until 12V is read.

Once the output voltage is verified, remove the battery and then solder the fan wires to the OUT+ and OUT- connections on the buck converter.

With the fan now connected, test the assembly again with a Ryobi battery and verify voltage at each segment with a multimeter. The fan and USB PD should both be functional and the switch should be functional.

Final Assembly

Using 4 of the M5x10 self-tapping screws, attach the Rear Fan Cover to the back of the fan. Do the same on the front side using Filter Housing Inner.

Align Filter Housing Inner with the Filter Housing Outer and slide 2 x M3x15mm bolts into the hinge to secure it.

Insert the carbon filter, then close up the , securing it with 2 x M3x8mm bolts into the heat set inserts.

Assemble the main hinge, using 2 x M3x40mm bolts and lock nuts.

Secure the buck converter to the inside rear of the Electronics Enclosure using 2 m3x5mm screws.

Set the upper portion of the Ryobi Mount inside the Electronics Enclosure, positive terminal facing out. Place the other half of the Ryobi Mount in place and secure with 9 x M3x20mm bolts.

Place the power switch and USB PD board into the Control Panel, securing the USB PD board with its clamp piece. The USB PD board will use 2 x M3x50mm bolts, screwed into the heat set inserts.

Guide the wire for the fan into the slot at the top of the Electronics Enclosure and make sure all the connectors are securely attached.

Attach a Ryobi ONE+ 18V battery and test the electronics one last time, testing:

• Toggling the power switch should start and stop the fan
• Toggling the power switch should allow the USB PD board to be powered
• The Ryobi ONE+ 18V battery should easily click in and be able to be released from the battery mount.

Once the above tests pass, set the lower hinge in place at the top of the Electronics Enclosure and close up with box by laying the Control Panel on top and securing it with 4 x M3x20mm screws.