Core One Activated Carbon Filter

Backpack design adapted to hold small loose activated charcoal granulat like this. It is designed around a mesh that gets glued into the lid and bottom of the charcoal container. For the mesh anything reasonably air permeable can be used. I used 140mm PC case fan dust filters like these. The filter attaches magnetically to the back of the Core One where the exhaust fans are. The printer does not need to be physically modified and the screws sticking out from the exhaust fans are accounted for in the design. To ensure that the charcoal is efficiently utilized the container has a honeycomb pocket design. After fitting the filter to the printer do not forget to set the filter setting in the printer settings to “DIY”.

Materials Required

• Filter Mesh, e.g. 1 x 140mm PC dust filter
• Magnets, standard design takes 6 6mm x 2mm Magnets (but can be modified in the Fusion design)
• 4 x M3 Screw 6-8mm (for the lid)
• 4 x M3 Heatset Insert
• Some Superglue
• 4 x M3 Screw 8-10mm (optional, alignment screws)
• 8 x M3 Nut (optional, alignment screws)

Printing Instructions

The .3MF project file and G-CODE for the charcoal container contain all required settings. The stencil and lid can be printed with any default settings.

Enable support but only on the build plate. If you enable supports everywhere the magnet slots (blue) will be filled in.

The magnets (6mm x 2mm) are embeded into the print. Add a pause when slicing before the blue holes get closed off and drop the magnets in. Do not place magnets in the red alignment holes.

Assembly Instructions

• To cut the filter in the correct size stick the cutting stencile to the filter with some tape and cut out arround it. The stencile is suitable for the lid and the charcoal container.

• Glue the filter to the bottom of the lid and the charcoal container with some super glue. There are some larger patches that are important but make sure to put some on the webbing in the middle too. You can use the cutting stencile to help you stick the filter down but don't leave it too long to not glue the stencile too. 
• Drill out or punch out the screw holes from the filter in the lid once the glue has solidified. 
• Insert the M3 heatset inserts into charcoal container. 
• Optionally: To align the filter on the exhaust fans you can take 4 M3 screws with some spacers or 2 M3 nuts per screw that you screw into the existing holes on the back of the printer. The filter has 4 alignment holes that then slot onto these screws thus ensuring good placement. 

Tips and Tricks

To fill the filter which could be a bit annoying place the filter on a container or large dinner plate, dump some granulate on it and shake it a bit do fill the pockets. The pockets should be filled and packed thight but dont overfill it or the lid might not fit on. If the lid bulges a bit in places because the pockets are a bit overflowing it should not be an issue since the filter holds the granulat down in the recessed design.

If you want to modify the magnet size you can use the parameters in the Fusion design. However it is designed for round magnets not larger than 6.5mm.