Fan duct/mount for E3D v6 addon w/ OE extruder housing

Here is my X-axis endstop model for anyone wanting to use the OE extruder housing. Still working on the fan duct,

http://www.thingiverse.com/thing:785951

I found out the hard way that you need it so it hits the endstop switch.

As far as the fan goes, I would need to know if it was readily accessible at most stores. It does seem like a good idea, but I think the regular 40mm fan will work just fine. I may however do both designs. I'm still working on placement of the duct because with the setup you see in the picture you lose about 40mm off the Y-axis.

I just thought the main body shaft/ column looked kinda wide.  I don't see why it needs to be bigger than a square cm or two.  That would keep the velocity up too.  Losing 40mm off the Y is going to be a deal breaker for most people.

It's better to gradually reduce the area rather than all at once.

There is a ton of over engineering in this thread. I whipped up this duct in 5 minutes and I've never had a problem. You're over thinking it. See attached photo. This design also doesn't sacrifice any build space.

I would throw out that acrylic extruder as well and get an Mk5 in place so you can properly mount the e3d with its groove mount.

Sure, here you go. I think this is the correct version -- if this doesn't work for some reason let me know. The L-bracket is specific to lawsy's carriages, but any type of mount will work. The fan is press fit into the shroud and held to the bracket with M3 bolts--you'd be surprised how snug it actually is even though the fan has no threading. Requires a 30mm fan. If this is the correct version then there should be 2mm or so of space between the build plate and shroud when homed. The L-bracket is flimsy, but I never got around to designing anything better because it just works.

If you plan on printing PLA with the fan always-on, perform your PID calibration with the fan running, because some air will pass over the nozzle--this is intentional as my design tries to cool the extruded plastic while not blowing significantly on the part. This allows extended fan use on ABS with extreme overhangs without inducing warping. I printed PLA at speeds of 100mm/s with no issues.

Edit: STLs are not in printable orientation. Print the shroud with the opening for the fan on the bottom! If you can't print it, point a desk fan at your build plate. It takes so little time to print that it won't warp.

Here is my latest duct mount. I'm still printing it, but it's close to the last pictures I posted.

http://www.thingiverse.com/thing:789720

In this community posts like mine are considered "constructive criticism." You can take it or leave it. It seems you have chosen to leave it which is fine. Just for clarification my shroud does not require supports if oriented as I suggested in the post above yours.

Additionally, static pressure doesn't matter as much as you think it does here. The maximum efficient velocity really isn't necessary. Thus why I used the phrase "over-engineering." I wasn't trying to insult you but I will defend my design by saying that I made a tradeoff between efficiency and space, and accommodated the lower efficiency by using a higher RPM fan with more kick. If you read about other solutions to this problem on the forums, you will see that others have done similarly.

Thanks Jago. Why is everyone so defensive on this forum any more? I guess I am one of the few that do not want to lose the 20mm of my build platform. Mine is only 150mm and 20mm is huge comparatively. Your design was exactly what I was looking for.

Just because his way works for him doesn't mean it's the best way or anyway better than mine and I hate when people come in imposing their ideas. He can go post his own thread for it instead of trying to derail mine. It's a real prick move.

There are many threads here that are started by someone, only to have others chime in with their ideas.  We don't call it derailing some much as it's variations on a theme input.

Anyway, back to your design.  I did a design nearly identical to yours nearly 2 years ago, and while it does work, it also has a few disadvantages. 

http://www.soliforum.com/post/22336/#p22336

One is noise.  The air rushing through the duct creates a lot of noise, then the other, and probably the biggest, disadvantage is the fact that it hits the front of the frame, before the printhead carriage reaches the maximum forward movement.

So I turned the duct around and had it lay on top of the motor.  Mine was designed to take 30mm fans, and was quite efficient, but eventually got replaced with something simpler. You will (eventually) find that simplicity is the mother of elegance, and you'll be a better designer for it.

BTW, here is my old thread.  The pictures are gone, because the server hosting them went dead, but the STLs are still there.  You might want to take a look.