4 Port Delta-P Fan Duct (Revo)

Update: May 27 2024

Update note: Version 25

• Redesigned the duct - outlet angles and ports. The duct was slightly off-center to the nozzle which has been corrected.
• Updated the Extruder cover to fit with this version.
• Updated the heatbed cable cover so the outlet ports don't make contact. To do this, I used M3 X 10 button head screws in place of the socket head cap screws to secure heatbed cables to the heatbed. This allowed me to reduce the height of the cover where the fan duct would make contact. 

Supports are needed for the duct. I use “from build plate only.” I've had good success with grid supports with Top Z contact distance set at 0.25mm.

I may tinker with the design a bit but I'm not sure I can make significant progress from here.

This version prints both test spheres well with fan speeds cranked up to around 80% after the first layer (no supports). I haven't tried higher fan speeds.  

Update: Apr. 11 2024

Update note: Version 24

• Deleted Version 23
• Realized I needed to adjust the extruder cover and fan duct so they mate properly. Files attached.
• Working on outlet ports to find optimal angle for cooling.

Update: Apr. 07 2024

Update note: Version 23

• Redesigned due to previous versions making contact with heat bed cover when printing near that area of the bed. This version clears the heat bed cover but the 50mm test sphere shows more deformations near the base of the sphere. I will attempt to tune it for better results. This version also requires bed supports which can be a hassle. I've been using grid supports as they give plenty of areas to grip with pliers. There is plenty of nozzle visibility available with this version. View of the nozzle and sphere deformations can be seen in the photos. The last 2 photos in the group are cleaner spheres made with version 17. 

Update: Mar. 20 2024

Update note: Version 17

• It looks like it may hit the heat bed cable cover when printing in that corner of the bed. May have to look at other design options. 

Update: Mar. 11 2024

Updates:

• Cleaner design with thicker sidewalls in certain areas.
• More nozzle visibility and centered.
• Ducting modified slightly.

Update notes: Version 12

• Running multiple sphere on a build plate causes deformations to reappear. My guess here is that the overhang layers don't fully cure when the printer is jumping around the bed. 
• I tested this updated version (V17) on a 50mm diameter hollow sphere (2mm walls) and it does well - better than version 12. But there are minor deformations on the back side of the sphere.

This is a design inspired by @teookie's delta-p duct. 

Teookie's V2R2 cover and mounting instructions are needed. Delta-P fan duct V2-R2 for MK3S(+) extruder by teookie | Download free STL model | Printables.com

This design has 4 dedicated outlet ports for cooling on all sides of the nozzle. 

I started down the path of designing this during Christmas 2023. I was attempting to print @3Dprinty's articulated snowman fidget when I noticed the spheres of the snowman were deformed in areas near the print bed. I tried the Delta-P and it improved the shapes but there were still opportunities for improvement. 

Notes:

Print with build plate supports

• This duct has been tuned specifically for this sphere. I haven't tried any other testing.
• This duct works with the E3d Revo nozzle. I have not tried it on a V6 machine.
• There is less nozzle visibility with this version compared to the original. 
• Sphere Photos
  • First two show deformations. These deformations were made with earlier versions of this fan duct. Other fan ducts I tried had more pronounced deformations.
  • Second two show no/minor deformations with the final revision of this duct.

Test Parameters

• Slice sphere with no supports.
• Set cooling max to 80 +
• Set fan to start after the first layer.

Fan Duct is completely redesigned. Extruder cover modified to accept the new duct.