AOOSTAR R1/R7 92mm Exhaust Fan Shroud

The AOOSTAR R1 and R7 are great budget NAS enclosures for backing up important files, but they have one significant airflow related issue, the stock top plate prevents smooth exhaust airflow out from the top of the unit and it stagnates air causing the 3.5" hard drives to heat up to 35-40C+ when the system is under load. This clip on style 92mm exhaust fan shroud completely eliminates the heat build up at the top of the units and drops idle drive temps ~10c for 92x25mm fan and ~5C for 92x15mm fan version.
 

Updates and Next Steps:

• Released Unsliced 3MF, and revised bambu slicer profiles which will allow you to avoid moving/aligning stls
• Added mesh only 3mf's (for those who do not want a circle for the center hub)
• Finishing up a 120mm variant, target release date by 07/01/2024, likely sooner. 80mm variant soon after that. 

Features:

• Universally Compatible with most 92mm fans (variant available for 120mm fans)
• Improves airflow by drawing air out from the R1/R7 chassis/base and reduce temperatures for all components. Can Reduce Drive temps by 5-10C 
• Clip-on on non-permanent attachment, does not require any modification to the R1/R7
• Uses standard PC case fan screws
• Low Profile / Sleek design does not change the overall look and feel of the R1/R7 and has minimal impact on overall height.
• Customizable mesh infill
• Addresses Heat Build Up as visible in FLIR imagery from the AOOSTAR R7 and R1 Review on 3dprintingbeginner.com
  AOOSTAR R1 (Left)                                                    AOOSTAR R7 (Right)
  
  Note: Above imagery is included with permission from 3dprintingbeginner.com

Materials Needed to assemble:

• 1, 92mm fans. I used a Noctua Noctua NF-A9 12v and Noctua NF-A9x14 12V in testing, but most 92mm fans should fit. 
  Note: 25mm Thick fans provide more static pressure and better cooling performance over 15mm fans.
• (4) standard pc case fan screws per shroud (to attach the 92mm fan)
• Wall Adapter to 4 pin 12v fan power supply. I used a cooler guys adapter found on amazon.

Assembly Notes:

1. Once printed, clean up any stringing on the mesh with a lighter/butane torch or snip tool. 
2. Insert fan into the shroud, Ensure the exhaust is pointing upwards once mounted. 
3. Insert fan cable in hole in the back that is perfectly sizes for any 3pin or 4pin fan cables. Suggest to rotate fan so that the cable is closest to the oval shaped hole
4. Flip shroud and Insert (4) screws in Z or X pattern and tighten evenly
5. Remove the stock top plate
6. Attach fan mount clip/'s to the R1 or R7, by inserting the front center first, then the rear (toward the cable/iopanel)
7. Power on the fan and your done!
    

Print Profile Notes:

Important Print Profile Notes: 

• If you are a bambu user I highly suggest using the bambu presliced 3mf files. 
• If you are not a bambu user, I suggest importing the unsliced 3mf. This will avoid any manual adjustment of the .stl placement, and only configuration in the slicer. Configure the mesh disc with the infill guidelines below. 

Nozzle: Suggest 0.4mm nozzle for precision fit
Wall Loops: 3 wall loops on 0.4mm nozzle, 0.6mm nozzle not recommended due to decreased layer adhesion.
Layer Height: Suggest 0.16 or 0.20 to maximize strength and reduce overhangs (0.20mm default )
Infill: 

• 15% gyroid on shroud and center disc
• 8% honeycomb on mesh desc (with no top or bottom layers, and 1 wall loop)

Brim: No brim default
Material: PLA for R1, PETG suggested for R7

• AOOSTAR R1 runs much cooler is is probably okay with PLA.
• AOOSTAR R7 runs warm so only advise printing in PETG for this model. 

Color: Any
Print Orientation: Print with mesh facing down
Supports: Snug Normal Supports. 
3d Printers: Should be printable on any printer.
Filament amount required: 65.03g for 92mm x 15mm version, 85.37g for 92x25mm version.