Summary

The hexagon hotend which I have mounted to my printer has the wires leaving the heat block horizontally and for ease of maintenance I did not want to bend them upwards and fit them through the x-carriage. Therefore, I needed a nozzle fan duct which was open at the front.

This is the design I came up with. It is a low profile fan duct similiar to many other designs, with the exception of a 90 degree cutout at the front, which leaves space for the wires of the hotend. The wire handling is IMHO better, particularly, when working on the hotend.

Having a circumferential slot for the air outlets did not work well enough with the single 50mm fan I was using. Therefore, I use separate outlets which are directed down- and sidewards. Works quite well (see picture with 50mm calibration tower).

Using the adapter bracket, the duct can be mounted to the standard Mendel90 fan bracket for the x-carriage.

Additionally, I have mounted 100mm white led strip, which looks quite nice when in operation. It is powerd by 12V always on, which I need at the x-carriage for the hexagon isolator fan anyways.

Credits to nophead for his excellent Mendel90 printer and polyhole library and to Chris Petersen for pie.scad (part or dotscad library - https://github.com/dotscad/dotscad)

Update 2014-12-21: for the hotend insulator fan duct (grey, on top of nozzle fan duct), see http://www.thingiverse.com/thing:603889

Instructions

The fanduct prints quite easily. No supports are needed, but your printer must be capable of bridging. As the fanduct is almost completely hollow, it prints quite fast, despite its size.

The bracket needs to be printed upside down.

My print settings are: 0.4mm nozzle, 0.3mm layer height, 2 perimeters, 25% infill.

The slot holes allow adjustment using the bracket.

The scad file is parametric, so you can change any settings as required (e.g. 40mm fan).

Mendel90 nozzle fan duct (90/360 open, for hexagon hotend)

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