Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor
 
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Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor  

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OPK
 OPK
(@opk)
Trusted Member
Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

This is based on the Prusa MK3 updated R3 (August 3, 2018) Extruder and has:

- 40x40x20mm Fan mounted without losing print volume
- Cooler Heatsink of Hotend due to improved airflow and more pressure
- Cooler extruder motor as some air flows into the idler compartment
- No heatcreep
- More air, more pressure, still silent and same printvolume
- Improved airflow by removing obstacles
- Before and after measurement done with Flir heatcamera

Design can be found here: https://www.thingiverse.com/thing:3072016
I named it the R3X 😉

My aim was to make that design even better by slightly adapting the airflow, but mainly by mounting a more powerful 40x40x20mm fan without losing print volume. To achieve that, the fan had to be moved a little to the front and then the interior adapted to that,

I bought a Flir heat cam to register any improvements in the design (see the old/new pictures) and though it is very far from exact science, Im pretty happy with this 5th iteration of my-redesign, therefore I am publishing it for others to use.

Some more measured temperatures while printing Benchy at 27degrees Celcius ambient:
Zlayer - Extruder motor temp - Heatsink temp - before/after the upgrade
9 - 44 - 60 - before
9 - 38 - 37 - after

18 - 45 - 62 - before
18 - 40 - 38 - after

25 - 46 - 65 - before
25 - 41 - 39 - after

28 - 47 - 68 - before
28 - 40 - 39 - after

32 - 47 - 67 - before
32 - 39 - 39 - after

A BIG BIG thanks to the official Prusa design team for the R3 extruder design and for publishing the design files.

Posted : 28/08/2018 6:42 pm
brims
(@brims)
Eminent Member
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Are you in negotiations with Noctua for a black fan? 😆
But in all seriousness, nice job, that's quite a heatsink temperature drop.

Posted : 28/08/2018 9:46 pm
OPK
 OPK
(@opk)
Trusted Member
Topic starter answered:
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Haha - I like the typical Noctua colors 🙂
Well the temperature drop all comes down to more air and a lot more pressure. Unfortunately I could not test with 35 degrees outside (when my extruder clicking started)... But you can feel it blowing through the design, and it is silent 🙂

Posted : 29/08/2018 1:22 am
surfgeorge
(@surfgeorge)
Estimable Member
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Very nice! Great work!

What's the exact model of the fan you are using?
I checked the different models of the Noctua 40mm fans and I realized that there are 2 versions of the 10mm fan, one with max. 8,2m3/h flow and one with 8,9m3/h. The 20mm thick A4 fan has a max flow volume of 9,4m3/h.
If the MK3 would be using the "weaker" one and the stronger A4 10mm one would be electrically compatible, that would be an easy upgrade without the modded extruder.

More infos here:
https://www.caseking.de/search?sSearch=Noctua+A40

Posted : 30/08/2018 8:41 am
OPK
 OPK
(@opk)
Trusted Member
Topic starter answered:
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Hi,
Dont look at the 10mm fans; the whole design (moving the fan to the front) is to install the 20mm fan (40x40x20mm) without losing print volume. If you replace the 10mm with a 20mm fan in the original design, the extruder will hit the left "pole" of the Prusa.
Im using the Noctua NF-A4x20 5V which has 3 pins and blows 9.4m3/h with a pressure of 2.26 mm H2O
https://noctua.at/en/products/fan/nf-a4x20-5v

Posted : 30/08/2018 10:51 am
gary.t4
(@gary-t4)
Eminent Member
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Hi I'm doing your project just want to know how to wire the new fan in ? Thanks Gary

Posted : 30/08/2018 9:52 pm
OPK
 OPK
(@opk)
Trusted Member
Topic starter answered:
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Hi Gary, you are replacing the left fan with another. I cut the cables close to the old fan and soldered a "3 pin (male) fan connector" to the wires. The Noctua comes with a 3 pin (female) connector, and clicks right in.
The removable fans are also great for other maintenance.

Posted : 30/08/2018 10:02 pm
gary.t4
(@gary-t4)
Eminent Member
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Could I just cut the wires on the old fan and solder to the new fan

Posted : 30/08/2018 10:58 pm
JoanTabb
(@joantabb)
Moderator
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

use heat shrink insulation... to prevent short circuit's

Joan

I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility. Location Halifax UK...
Posted : 30/08/2018 11:07 pm
gary.t4
(@gary-t4)
Eminent Member
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

I will Joan thanks for keeping a eye on me did you install the new extruder parts ?

Posted : 30/08/2018 11:10 pm
JoanTabb
(@joantabb)
Moderator
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Hi Gary,

no I haven't installed the new parts yet,

I have an MMU2 on order... and will get new parts with that... which I will use on my Mk3,

I have printer new R3 parts for my mk2.5 upgrade, but not started that yet!

regards Joan

I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility. Location Halifax UK...
Posted : 30/08/2018 11:24 pm
gary.t4
(@gary-t4)
Eminent Member
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Wow mmu2 watched a utube video today nice

Posted : 30/08/2018 11:36 pm
barry.i
(@barry-i)
New Member
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

I don't see the real value of increasing the width of the fan 10mm. The CFM on the recommended by E3D-V6 is 4-5 CFM, but they have a simplistic light weight shroud attached to their 30mm fan, that produces 4.1CFM. Prusa uses a Noctura 40mm that produces 4.8CFM, but the hotend is also surrounded with much more mass, that is both absorbing and emanating thermal energy. The 20mm wide fan outputs 5.5CFM.
The R3 upgrade helps with the use of the Coandă effect, but we are talking of about only a 23% increase in airflow for the fan change.
The Noctura 40mm is 17dB(A), nice and quiet, but lacks flow. I don't just print PLA, but hotter materials, including Polycarbonate. A myopic improvement is not viable for me. I simple spec'd out a different 40x40x10mm fan, 5vdc, 3wire and not loud. I picked a Sunon Fan, part number MF40100V1-1000U-G99, 7000RPM, at 8 CFM and a noise level of 27.3dB(A). Stock R3 or R2 parts will work, and the flow improvement of a 32CFM increase works well for me.
I put a plug on the cable and made it so I can change fans on the fly, but so far, I have not gone back to the low flow fan

Posted : 02/09/2018 7:28 pm
OPK
 OPK
(@opk)
Trusted Member
Topic starter answered:
Re: Adapted version of the new R3 extruder to fit a 40x40x20mm fan and allow for a cooler extruder motor

Thanks for your response. Luckily there is no need to use it if you don't want to. I'm just giving options. For me it works so well that I will use it, even with the MMU2 option. I don't have the extruder clicking anymore and the temperature is measurably lower and I can now fully close my enclosure. The benefits come from the increased pressure, not the airflow. You need a fan that is capable of pressing through the cool part of the hot end. That is the reason I also removed material (mass) there,
Besides that, the Sunon with over 27dB sounds like a jet engine - at least to me 😉

Posted : 02/09/2018 8:03 pm
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