Remixed Advanced Filtration for Prusa CORE One

Description

Here is my version of an active filtration system for the Prusa Core One.

It uses designs from the filter by CNC Kitchen and the advanced filtration by PeterLu.
This filter use the same vacuum cleaner HEPA filters, activated carbon and foam strips that CNC Kitchen used.
Then the same fan and fan mounting bolts/nuts used by PeterLu.

Parts needed to print:

-1x Filter Case
-1x Fan Cover
-1x Exhaust Grille
-1x Filter Basket

There are two versions of the filter basket:

-Version with 3mm hexagon holes at the bottom.
-Solid version that requires a modifier to add a mesh infill pattern (just like in CNC Kitchen's original version)
You can use the included modifier mesh to make your own, or open the .3mf file to use as a starting point (it already has the modifier and basic settings in it).

Optional part:

-Exhaust Diverter
Used to divert the air back behind the printer, instead of straight out to the side.
If you want to mount something else to the side, the mounting for this uses two M3 bolts spaced 16mm apart.

Recommended to print everything with a filament that can handle a bit heat, such as PETG and better.
Supports (supports on build plate only) should be used for the Filter Case, Filter Basket and the optional Exhaust Diverter.

-Filter Case needs support for the cable hole and exhaust hole. Might as well add supports for the M4 nut sockets at the bottom too.

-Filter Basket needs supports for the bottom slots. (for foam strips)

-Exahust Diverter

Hardware required for the filtration parts:

-4x M3x30mm bolts (for mounting the entire filter to the printer)
-6x3mm foam sealing strips (I used some cheap stuff from Amazon, ASIN B09PR84CZG)
-Vacuum cleaner HEPA filter (126 x 47 mm). (Such as ASIN B09HHM1YRR)
-Air filtration activated carbon.

I would also recommend using some generic vacuum cleaner thin filter mat to prevent charcoal dust getting blown out. Cut into a circle and placed inside the basket before adding the activated carbon. Such as ASIN B086PFYJZ7.
You can print and use the round plate modifier from the “Solid Basket” folder as a cutting template.

Hardware required for the fan parts:

-3x M4x8mm bolts
-3x M4 nuts
-1x 12032 blower fan
I used the 24V fan from this kit. It needs to be a 12032 blower fan, and that one has the correct plug for the Prusa Core One. Most fans I found would be required to be hardwired or powered by other means.

Optional hardware:

(If you want to use the air diverter or mount something of your own design)
-2x M3x10mm bolt
-2x M3 nuts

Assembly:

After printing everything and getting the hardware, assemble it in the following steps.

Optional: If you want to use the exhaust diverter (or something else of your own design), Push in two M3 nuts to the sockets on the inside. Easiest is to pull them into the sockets with an M3 bolt from the outside.

-Push the Exhaust Grille into the square hole from the inside of the case. It has a lip sticking out on the side that goes into the slot in the corner of the case. It should be flush with the outside of the case.
If it's to tight of a fit you might have to sand a bit off from the edges of the hole. It could be because the top edge drooped to much when printing.

-Route the fan cable through the oval hole, and then lower the fan into the case. Naturally, the fans exhaust should be oriented to the exhaust grille.
Then bolt the fan in place with the M4x8mm bolts.

-Add the Fancover on top of the fan. The side with the arrow should be facing upwards, and should be oriented with the arrow pointing away from the cable slot. When mounted to the printer, the arrow (red) will point upwards and the cable (circled in yellow) will come out the bottom.

-Add foam strips to the bottom and top channels of the Filter Basket.

-Add recommended filter mat to the bottom of the filter basket.

-Add activated carbon up to the ledge where the HEPA filter rests.

-Push the HEPA filter in place.

-Lower the Filter Basket down into the Case, orienting the arrow on top in the same direction as the fancover (pointing away from the cable hole).