Voron V0 Auxiliary Fan Ducts

About Voron V0 Auxiliary Fan Ducts

These are auxiliary fan mounts for the v0, which you can use if you need extra cooling on your Speedbenchy journey.

The ducts can be easily installed after the Printer has already been fully assembled, as there are mounting options that don't require preloaded nuts in the extrusion slots.

Since the R1 release there are now 3 mounting options:

1. (Legacy) Clamp-Mount: this one just clamps the duct to the bottom extrusion. This was a easy way to secure the ducts, however the ducts were prone to come loose from vibrations and could tilt into the print volume, colliding with the toolhead. This version is no longer recommended.
2. Screw-Mounts to secure the bottom and top of the ducts to the frame. These allow the most secure installation, however you will need preloaded M3 nuts in the slots of the extrusion (2 at the bottom and 2 at the top). Due to space constraints installing these Mounts (especially the top ones) can be rather difficult on the larger fan ducts with the frame assembled.
3. Twist-Mounts that get inserted into the extrusion slot and twisted 90° to secure to the frame. These provide a very solid mount while not needing preloaded M3 nuts and therefore are the recommended installation method for already fully assembled printers. If these are to tight or to loose after installation you can adjust the CAD-Files to improve the mount, a guide is provided on my GitHub repo.

All of these mounting options use the same main duct bodies, so you could also mix and match as you want. For Example if you used a Nevermore filter before you could use the 2 M3 nuts in the bottom extrusion to secure the bottom of the duct with a screw mount and the top with the twist mounts.

No matter what mount you choose it is highly recommended you use one of the top mounts to ensure proper alignment towards the print bed and avoid the duct to collide with the toolhead.

A Overhang comparison test between all  the options can be found on the GitHub repo. This is currently outdated as these tests used the pre-R1 ducts.

A list of required parts for each version, assembly instructions and options for connecting the fan can be also found on my GitHub repo:

• 5015
• 6028
• 7530
• 9733
• 12032

No CFD Simulation has been done on these so these could most likely be improved, however they seem to work quite well as is.

There are also Variations of the duct that are 3mm shorter, to better target the airflow for longer toolheads than the stock Mini StealthBurner over on my GitHub. There also is a guide on how to adjust the Fusion360 CAD-File to a specific height.

Warning about Tolerances

There seems to be quite a bit of variance in the exact mounting hole patterns on these blower fans, especially the larger ones. So you could run into compatibility issues and need to adjust the model in CAD. I used GDSTIME fans for all my tests so these should work.

Additionally the width of the slots on the MakerBeamXL or LDO Extrusions can vary a lot. These generally are specced at 3-3.2mm wide. The ducts were designed with a 3.2mm thick part that slots into the extrusion. This was made to ensure a snug fit, however on some frames it could be very difficult/impossible to slot in. So either you can just print it and sand down the bottom part if needed or measure your frame before printing and adjust in CAD for the measured slot thickness.

Firmware Configuration

There is also a Klipper config file on my GitHub to make using this fan easier, including a entry to the Display to control the fan and modifications for the M106 and M107 G-Codes to allow a Slicer to control the fan through G-Code (like BambuStudio or OrcaSlicer).

Printing

All ducts (except 120mm) are provided in 2 versions:

• Unibody if you have a larger printer (~170mm)
• 2 Part to print on a v0 sized printer, these parts will need to be glued together after printing.

Print Settings

0.2mm layer height, 2-3 perimeters, ~25% infill are more than enough.

All files are already oriented the correct way and supports are built into the files.

Credits

Thanks to the Voron Team for their great work on the V0 Printer: Voron Design

Following Fan Models were used in CAD:

• Radial Cooling 5015 Fan (50mm) DC12V by Aleksandr Ivanov
• Basic 6028 Blower Model by kelvinA
• Gamma 28 Blower Fan 76×30mm by Pokai Chang
• CBM-979433S-125-467 by CUI Devices
• CBM-A232B-120-457 by CUI Devices

Changelog

2024-02-14:

• Added a stronger variant of the bottom twist mounts. These don't rely on layer adhesion nearly as much as the original design and therefore should be a lot stronger. However you will need 2 additional Heatsets and M3x12 screws.

2023-12-23: R1 Release

• Updated slot-bar to be a bit flexible and increase compatibility with different extrusion slot widths, while still providing some stiffness

2023-08-15: R1 Release

• Remade all ducts to make CAD cleaner, wall thicknesses more consistent and the design more consistent overall
• Adjusted ducts to reduce back pressure and improve overall cooling performance (12032 Version seems to still have a bit of a backpressure issue, but is far better than the old design).
• Increased thickness of bottom bar that slots into the extrusion for more rigid mount. Tolerances of these slots are quite big, so on some frames it could get tight.
• Added Cable-Channels to rear for tidier wire routing
• Added Screw-Mounts for the bottom and the top of the ducts (Require preloaded M3 nuts)
• Added "Twist"-Mounts for the bottom and the top of the ducts
• Improvements to Supports, resulting in better print results. However these are slightly harder to remove.
• In addition to STEP Files I also exported the source Fusion 360 Files, allowing for easier Modification and understanding of how these ducts were created.
• Updated Documentation to reflect these changes
• Added links to the used CAD-Files for the fans

Changes made to ducts to improve cooling performance:

• 6028: Duct Outlet is now 85mm wide (before 80mm)
• 7530: Duct Outlet is 90mm wide and 3.5mm high (before 80mm and 3mm respectively)
• 9733: Duct Outlet is 100mm wide and 4mm high (before 80mm and 3mm respectively)
• 12032: Duct Outlet is 110mm wide and 5mm high (before 90mm and 3mm respectively)

All had slight changes to the internal flow guide geometry to (hopefully) improve cooling performance.

Known Issue: The 7530 duct still has higher airflow at the left side than on the right side, at least at 100% speed. Will need to rework the internal flow guides some time in the future.

2023-06-24: 

Change 12032 Duct to be centered to allow better alignment when installing it on the left side of the printer.

2023-05-30: 

small visual updates