Big Update

After a while even with PETG the close distance to the Volcano Block made one of the Arms soften and hang a bit.
Also I tested multiple hole Sizes and learned that I underestimated the static pressure that is working against the fan. The small long holes were to restricted and lowered efficiency! (Even tho I got quite good results with it)

The Version 2 has mainly 4 changes:

• Bigger holes, bigger Air Channels, much more airflow!
• The Arms are wider apart and leaving more clearance to the Heater Block!
• Walls are now thicker wich allows to be easily printed when using larger nozzles
• IR Probe is now on the other side

Version 3 (additionally to V2 Changes):

• IR Probe is now mounted to the Mount itself. Z-Offset with V3 is about 1.5mm to the nozzle of an Volcano Block! But this is very dependent on the Bed Material!
• Definitely wont fit standard V6 Block!
• Step file for Mount is uploaded too. If you want to fork it for BL-Touch or something just do so!

Version 3.1 (replaces 3.0)

• Arms 2mm shorter and thus holes closer to fan, better Air-Focus around nozzle.

Original Text

This is my take on an quite universal compatible Titan Aero Fan Duct.
Since I upgraded my Titan Aero to the Volcano Hotend, no Fan Ducts I could find convinced me. Most were Printer specific, some did simply not cool good enough and nearly all blocked mounting positions for my DC42 IR Sensor (wich I love).

So I decided to create my own Fan Duct, wich took many hours, over 30 iterations and I tested and optimized them with some amateurish CFD simulations.
It maybe is compatible with V6 (see below)

The last 3 pictures are from a 50% scaled down print of the ksr_fdmtest printed with a Volcano Nozzle of 0.8mm sliced to 0.6mm line width and 0.2mm layer height using the Fan Duct.

Where my Fan Duct is great:

• Cools the hot filaments quite good
• Height adjustable
• Can be mounted with the DC42 IR Sensor (I can highly recommend it, but ignore the mounting points if you don't have one)
• because it just mounts directly to the Titan Aero, its highly compatible with many Titan Aero Mounts and Printers
• doesn't need support to print (if you rotate it correctly in your slicer)

Where my Fan Duct isn't great:

• Probably a bit heavy (~35g) because its optimized to be printed with a 0.8 Nozzle (0.4 should of course just work as well) and I really wanted to limit the wiggles of the construct since it holds the Z sensor!
• looks chunky

Where my Fan Duct maybe is good?:

• maybe compatible with regular V6 Hotend too (I won't downgrade back but if somebody could test it and give feedback, that would be great!)
• if it isn't compatible with the V6 Hotend, please give feedback and I'll try to make an compatible Version, probably the claws must be spread a bit more?

What you will need:

• 50x15 Radial Fan, I highly recommend a good one with 6000 RPM from Sunon! Cheap slower ones strongly decrease the cooling!
• You need 2x long enough M3 Screws, as the Mount takes additional 3mm at the Screws (it simply replaces the distance rings for the Titan Aero Mount I use)
• You need 2x 20mm M4 Screws for the Fan, 25mm should work too.
• Use a material like PETG or ABS at least for the Fan Duct itself, because PLA won't withstands the heat for long!
• Print it rotated correctly (like on the Cura Screenshot)

How you should install it:

• Make sure the Heater Block is rotated in a way so that it fits between the two claws of the Fan Duct
• Install the Mount
• Put the Fan in the Fan Duct and the Screws through it
• Position the Fan Duct so that the height-clearance between the underside to the nozzle tip is like 3-4 mm (or 2-3mm from the IR Sensor)
• Screw the M4 Screws into the long holes of the Mount (they will cut their way in it)
• connect the fan correctly
• re-calibrate the offsets of the IR Sensor if you use it!!