WS7040 CPAP fan mount for aluminum extrusion (Voron 2.4 compatible)

This is a mount for the WS7040 fan and its driver PCB. It is meant to fit on an aluminum extrusion. Tested to fit a Voron 2.4 but could probably fit several other printers as well.

I've tested it to fit at the back of a Voron 2.4's gantry inside the enclosure. One advantage of using the fan inside the enclosure is that you can maintain negative air pressure and reduce the chance for air leaks. Another advantage is that it reduces the overall noise. The box also has some cavity that you can fill with some material like cotton to further reduce noise.

Hardware (includes affiliate links):

• 8 x M3 heatset inserts
• 3 x 8mm M2.6 self-tapping screws (https://amzn.to/3pu98mx) to attach the fan to the box.
• 6 x 8mm M3 SHCS
• 2 x 12mm M3 SHCS
• 2 x 10mm M3 SHCS
• 4 x 10mm M2 self-tapping screws
• CPAP hose (https://amzn.to/43daGiy)
• WS4070 fan (https://s.click.aliexpress.com/e/_DDgxJ5h)

Printing the parts:

• Use the traditional Voron settings
• You might want to use some mouse ears on the box's tabs to avoid possible warping (See for example this video for some tips: https://youtu.be/XJgQig2XhBw)
• The filter part is used to reduce noise. To print it, remove the top & bottom walls, set Gyroid infill. I'm personally using 40% infill. You can try different settings to suit your needs. Higher infill should reduce noise, but could also reduce performance. Depending on how much Y clearance you have at the back of you printer, you could also scale up or down the filter's size (on the Z axis in your slicer).

Important warnings:

• You might need to reduce your printhead's maximum Z position (stepper_z.position_max in your Klipper settings) to provide enough clearance for the fan hose and CPAP hose. For my 300x300 Voron 2.4 I've set it to 235, but your mileage may vary.
• Make sure you have enough Y clearance at the back of you printer so that the printhead cannot accidentally run into the fan box. You'll need at least 65mm of clearance.

If you're interested, check out the Voron Stealthburner mod I've made to connect the CPAP hose to the toolhead: https://www.printables.com/model/513437-stealthburner-mod-for-cpap-lgx-lite-and-sb2040

Credits: Source models for the WS7040 fan and PCB that I've used as reference to design this model: https://grabcad.com/library/cpap-blower-fan-ws7040-24-v200n-driver-ws2403dy01v04-1

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