ENDER 5 & ENDER 6 DUAL 40MM FAN HOT END DUCT / FANG, no support, micro swiss direct drive and bowden compatible

Briss Moto design

Just to make things clear, my designs are protected by copyrights laws. It is not authorized to distribute or sell any of my designs without prior written authorization from myself. Even if you modified my original design. Thank you

New V4.4 with tip angle corrected for better airflow orientation, Built-in BL-touch/CR-touch mount (Offset: X = 44mm, Y = 7.5mm). Printing with the built-in CR-touch mount does not require supports at all. BL/CR touch mount, the holes don't go through for a very specific reason. It's a single layer that doesn't go through, it allows to print bridges across so you don't need supports to get that part printed properly. Then you trim off the single layer to clear the holes. I did that because when you try to print a bridge that has a hole in the middle it does not print very pretty, or you need to add support which adds a lot of time to the print for nothing. Now it prints well without supports and takes 10 seconds to trim off the single layer for the bolts to go through. Enjoy :)

Update 04-05-2021: Adding ender 6 models, upgrading all to V4.3 (slotted mount holes for 2mm height adjustability) and adding "fan duct up V2" which has integrated grill. It's more tricky to print because of the small features so i'll leave both files on here.

Update 6-03-2021:
-Adding compatible files for Micro swiss direct drive carriage. Again available with or without LED's
-Adding BL touch bracket

Update 25-02-2021: V4.2 Now available with integrated LED lights (5mm straw hat LEDs up front and possible to put a 20mm star inside). Both files are available, with or without lights. It's a little more tricky to print the one with lights, has small features.
V4.2 : -made the mid bolt tab larger, more robust and easier to print
-slotted the wire hole for the front fan

So you can fix 4010 or 4020 axial fans of your choice. With tool less push pins or M3 bolts. Built-in recesses for the M3 nuts (5.5mm wide across the flats)

-includes optional add-on part that goes under the hot end fan to complete the duct to get absolute maximum efficiency. leaving this as a separate part from the fang because it would prevent from printing it without support. Just glue it in place after
-Chimney at the right to zip tie your wires (prevents the wires from breaking at the heater cartridge base)
-Tiny hole in the front to put the allen key through the fang to access the rear middle bolt (this bolt is optional tho, 2 bolts holds it pretty tight already)
-Rear bolt is inserted from the back through the slot and needs an M3 nut to be inserted from inside the fang.
-STL for the front fan duct to prevent sucking every debris and filaments from the build plate. Prints without any support, just lay it flat on the fan flange. For installation you need the longer push pins (STL named "holder pin 4020 fan + duct")

The idea behind this project was to be able to use two silent 4020 fans. I used a sunon MF40202V2-1000U-A99 fan (bought on digikey for about 5$). I added a 330 ohm resistor to reduce speed and noise (brings down the voltage to the fan to about 18v).

No BLtouch mount yet, i'll see if i can come up with something.

Orbiter direct drive extruder mount
https://www.thingiverse.com/thing:4885389

Ender 6 BL touch bracket for V4.3, Thanks to Jan for the design
https://www.thingiverse.com/thing:4947955

Elias did a super nice install video of the fan on his ender 3 V2 if anyone wants to have all the details on how to install this.
https://www.youtube.com/watch?v=MQC6NVd42q0&ab_channel=Randomecticly&fbclid=IwAR2KmPdp5_auHxrN__kBUmhRZAtyqxc8Zgz6rmZ_RI7E9oedNEcYEx_3A6c

Prints without any support. Just lay flat on the top fan flange as pictured and you're set. The duct also prints without support, laying flat on the flange as pictured.

Ideally print out of petg, it is more flexible and durable than PLA but it does work out of PLA. Push pins are better made with petg too since it's more flexible. PLA is a little stiff for those and you might have issues to put them on.

Print with 0.4mm nozzle with 0.2mm layer thickness. About 20% infill works great