This is a fan shroud that replaces the one that comes with the Raspberry Pi 5 Case and supports the Official Active Pi 5 Cooler. Typically you would have to remove the standard fan shroud as the active cooler's fan is in the wrong position to that which comes with the case.
Without the stock shroud hot air can rise and get sucked back into the enclosure by the down draft fan. In the original design the GPIO Access hole is actually sealed off by the lid preventing hot air from escaping by rising upwards via the gap in the shroud.
I believe the intention of the Pi 5 Case designers is to suck cold air in from the lid area above the shroud and blow it directly on the metal heat sink's below the shroud. The positive air pressure below the shroud is greater than that out side the case forcing the hot air to be expelled via the vent in the base of the case under the Pi's PCB, also creating cooling airflow for the components under the PCB.
This shroud copies the same principle just that the fan inlet has been moved from the default location to the new location where the Active Coolers fan sits, removing the need to remove the stock shroud. The new shroud also improves on the cooling of the Active Cooler without any shroud at all by creating the same principles of the stock case cooler and fan shroud.
Printing Tip's
1). Use heat resistant filament with good layer adhesion. ABS / ASA. I have tried PETG but found the securing tabs break off after a couple of inserts. You may want to use a bit of superglue on the bottom section of the two end tabs to improve the layer adhesion. I would not use PLA because of its warping under heat.
2). 0.4 mm Nozzle … this is an intricate model and those fastening tabs are only 0.5mm.
3). 100% Infill and 3 wall layers. Again an intricate model that needs as much rigidity as it can get.
Installation Tips
The shroud is removed by taking the top off the case, then remove the middle section. The fan shroud is then removed by pushing it from underneath at the top end (furthest away from the USB Side of the Pi 5). There are two retaining tabs that need to be pushed back. Installation is the reverse. there is a long alignment tab that gets inserted first on the USB side. Then press the top end of the shroud down and the clips should click and secure it into place.
Any suggestions to improve the design let me know. I tried to keep as faithful to the original as I could but injection molded parts are stronger than FDM. I tried to keep it as simple for people who don't have multi filament capability otherwise I would have fixed this with TPU and ASA.
Apologies if this does not work for you and your printer. Happy to make improvements as my testing progresses.
Update: Some people have reported that the fan shroud fan depth ~ 3mm is a bit to deep for their implementation. So I have also uploaded a version that is just 2mm deep. This I suspect depends on the thermal pads / paste you use. I used TF8 Thermal paste not the provided thermal pads which I suspect are thicker that paste and was causing the issues.
Thermal Pads: Use the 2mm Model
Thermal Paste: Use the 3mm Model
Also added a version with holes for MPI 3 x Cables (Currently Untested), and obviously the airflow wont be as good with the MPI Version
The author marked this model as their own original creation.