S5 Butterflyhead - optimized part cooling

[foehnsturm 969]

Hey guys, long time no see here.

 

First of all, I'm happy that the Mark2 community is still alive (and kudos to @tinkergnome for doing the support work!)

 

So, here's a small project which addresses one of the weaknesses of the S5 design: Prints which require good cooling, particularly with PLA and/or of smaller size, are really not among its specialties ...  Printing with core1 shows even worse results than with core2 and walls facing left generally suffer more. 

 

There are two main reasons for this. First, introducing radial fans with the UM3 was a good idea but their positioning was - at least in part - driven by design criteria instead of functionality aspects. Air doesn't come straight out of these fans but more like in a 45° angle.  As both fans are sitting behind the nozzles, this is a good thing for the right one, which blows to the front, whereas the left fan mainly blows backwards to nirwana. Second, there's only minimum clearance underneath the print head. Air cannot reach the nozzle tips directly but has to be diverted, which creates back pressure and reduces air flow. 

 

As UM hardware designers still freak out when they make optimum use of space, I suppose 😜, there's literally no space left to change the setup. Like only 1-2 mm to the side walls during homing or nozzle switching. But I wanted these fans to throw more air to the place where it's needed. After two days of brain racking, I thought the design should make use of another dimension: time. The head has to change shape.

 

• fans are folding in and out
• left fan flipped upside down to direct the airflow to the front
• almost directly pointing to the nozzles
• replaces the bottom housing of the original head
• printing time (3 parts): 3 hrs
• time to mount: 15 min

 

Part files will follow very soon. Stay tuned 🙂 

 

 

Edited February 6, 2020 by foehnsturm

[Smithy 1,141]

Great idea, great design!
Can you please also give some advises how to print it, I guess support is needed and some material with a higher glass transistion temperature would be a good idea.

 

Thanks a lot for your work!

[foehnsturm 969]

The housing will print well in original orientation or upside down but needs a little support in both cases. The fan holding brackets are  simple 5 min prints.

 

As for the material, original parts are some kind of ABS, I suppose. So, UM already made sure to not expose it do direct heat from the print cores. Therefore any material which withstands  at least 80°C permanently (or 100°C if you heat the print bed to maximum temp) should be fine. I used greentec pro.

[Smithy 1,141]

Thanks! Will give it a try on the weekend.

[foehnsturm 969]

STL files are here

 

You need to print the fan bracket twice, obviously. As mentioned above, the housing part needs support. 

I used standard settings and 0.15 mm layer.  And for support set overhang angle to 90 and touching buildplate only.

 

The fan brackets will bend as long as there's no fan inserted. Thus they can easily be put into place.

The four screws that are holding the bottom housing might interfere with the fans when folding up. I did cut them a little but you could also print tiny shims. 

Edited February 6, 2020 by foehnsturm

[ultiarjan 1,223]

that's what I call 'out of the box' thinking 🙂

will give it a try for sure. think I'll have to print a few 'before' prints first...

 

oh and the small print was not flat on the bed after loading in cura, so just use "lay flat" before printing..

 

Edited February 6, 2020 by ultiarjan

[foehnsturm 969]

Oh thanks, I checked with 0,15 mm first layer, obviously not precise enough.

Fixed and uploaded.

[Smithy 1,141]

In progress.....

[Smithy 1,141]

If the print head could only guess what it is printing. 🙂

 

This is like a reorganization in a company where the project manager has to rationalizes his own job.

[ultiarjan 1,223]

not the best colour to combine with white..... but Greentec pro...

 

[Smithy 1,141]

Colour like from a smoker's household 🙂 

[foehnsturm 969]

 50 shades of white ...

[Smithy 1,141]

Ready for the first test print

 

[Smithy 1,141]

Left side butterfly head, right is original

 

 

 

 

 

 

 

 

I guess it needs some more models to test, this was just a quick test to see if it works.

The bridge test is slightly better with the butterfly head, which is the result of the better airflow of the fans.

[foehnsturm 969]

To which side the overhang was facing during printing? 

[Smithy 1,141]

To the left, as on the 4th picture.

[foehnsturm 969]

Ok, I got an idea why. Thinking about some modifications.

[RudydG 62]

This is an easy upgrade, will test it out.