Tevo Little Monster - Volacon Fan Duct with DC42 IR Sensor Mount

The part is designed to go with the Effector strain relief I designed
https://www.thingiverse.com/thing:2852262

I changed out all the counterfeit parts in my Tevo Little Monster, this ranged from changing the control board out to Duet Wifi right down to genuine E3D Volcano hotend and Titan extruder. As a result I also needed to replace the crappy & heavy fan ducts that came with the Tevo LM as well as make a spot for the IR sensor to mount on. The original fanduct had the air flow going everywhere including down onto my high temp plastic prints which was bad for warping. The original design also had problems with most of the air flow being able to go around the heatsink rather than through it causing clogging issues with an all metal heat-break. However this item will also work with the hotend that came with the Tevo LM as standard, it just won't facilitate the crappy BL Touch.

The primary focus of this design, other than allowing a legitimate E3D Volcano hotend, was to reduce the overall footprint of the cooling fans. With the fully enclosed heated chamber on my Tevo LM the original fan ducts stuck out much further than the actual effecort which meant it smashed into the enclosed side walls. By reducing the sive of the fan ducts to stay inside of the footprint of the effector means the effector and connecting rods are now the limiting size factor and allows the enclosure without collisions.

The design not only forces all the air through the heatsink fins and concentrates the air where it is needed without causing a drop in in airflow or allowing air to leak out into the print below, it also incorporates a dual fan mount to push-pull the air through the heatsink. The push-pull makes a world of difference on the notoriously finical E3D volcano hotends when using PLA, fine nozzles (0.25-0.4) and super fast head and retraction speeds. I also have a enclosed heated chamber on my Tevo LM which means cooling must be done super well which the dual fan setup really works well when printing Polycarbs. I also changed my 30mm fans from the crappy low flow and pressure E3D ones (3.5cfm) to much better dual ball bearing ones that move 5.6cfm & triple the pressure.

The mount reuses the blower fans that come on the Tevo LM, these are the best design for 3D printer fans IMO as it is perfectly in between air volume and pressure with a low noise. I personally replaced my fans with ones that move 11cfm (up from 7cfm on the originals).

The design also incorporates an area to keep the heater wires aware from the heat break and routs them up the back of the effect up under the IR sensor and keeps everything in place out of the road and unable to get accidentally caught on something. This also makes the whole look much cleaner and provides easy access to the front of the hotend and fan filter (if you choose to use one). The fans were moved out far enough to make adding/changing a silicon sock easy as well as facilitating enough room to put a spanner on the hotend enabling the changing of a nozzle to be a breeze with the easy access.