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Description:

This is a faceplate for the sides of the bottom section of the Rostock Max v2 that will hold an 80mm fan. It is to allow for air exchange that is more robust than the stock PSU fan which runs at idle nearly all the time.

Version: v1.2
Date: 11-1-14
Photos: (n/a)

Downloads:

Repables: http://repables.com/r/425/
Bitbucket: https://bitbucket.org/redoverred/80mm-f ... e-for-rmv2

License:

This work is licensed under the Creative Commons Attribution-ShareAlike 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by-sa/4.0/ or send a letter to Creative Commons, PO Box 1866, Mountain View, CA 94042, USA.

Version History:

v1.2: Fixed overall dimensions of plate.
v1.1: Fixed hole dimension.
v1.0: Initial.

Was working on something similar and stopped when I saw this, as your tools and skill are way beyond my current level.

Printing a v1.0 right now. Initial impression is that the holes for the thumbscrews need to be larger. Factory part has holes >5mm. Holes as printed are about 3.5mm id. Being oversized to 6-7mm would be OK, as the thumbscrew has a wide collar.

Earthbound wrote:Was working on something similar and stopped when I saw this, as your tools and skill are way beyond my current level.

Printing a v1.0 right now. Initial impression is that the holes for the thumbscrews need to be larger. Factory part has holes >5mm. Holes as printed are about 3.5mm id. Being oversized to 6-7mm would be OK, as the thumbscrew has a wide collar.

Good to know, I'll change that right away! I went by the size on the CAD file for the part from the SeeMeCNC github, but I suppose that would be the size needed to thread the screws.

From my very limited experience with manipulating 2D CAD files (layouts for laser cutting) into 3D software for STL generation, test output from the printer has usually required that I go back and offset all interior dimensions by about .5mm, after allowing for laser kerf difference.

I don't know if that just happens to coincide with the nozzle width... Perhaps the slicer software compensates extruder path for exterior dimensions only and interior must be edited manually.

Print is just over 50% complete. Thought about stopping it and waiting for v1.1, but I'm going to let it finish. The white PLA I'm using has been giving my some trouble on other objects and I cranked the temp up a bit for this print. Infill looks much better.

Next possible issue...

What are the outer dimensions of your design? The melamine side cover piece on my RMv2 is approximately 200 x 114 mm. Matter Control says the piece printing is 206 x 115. I'm thinking that perhaps you started from the dimensions of the frame behind the cover, since you would have referenced it for fan clearance? That would also help explain the hole diameters, since the frame's hols are undersized for threading and would be made even smaller since the CAD files would likely have a laser kerf allowance.

Earthbound wrote:Next possible issue...

What are the outer dimensions of your design? The melamine side cover piece on my RMv2 is approximately 200 x 114 mm. Matter Control says the piece printing is 206 x 115. I'm thinking that perhaps you started from the dimensions of the frame behind the cover, since you would have referenced it for fan clearance? That would also help explain the hole diameters, since the frame's hols are undersized for threading and would be made even smaller since the CAD files would likely have a laser kerf allowance.

Ah, didn't think about the laser allowance. I should have really taken some measurements here eh? I'll change it to 114x200 right away. I guess I got ahead of myself posting the file, sorry!

Edit: Alright, the file is up there and it is 113.5x200 mm now. I am printing it myself, but I took measurements from the board itself this time to make sure it would work. I seriously am sorry about wasting your plastic with my "beta" version, from now on I should probably test things myself, but I just didn't want to print it until my white ABS came :/

No worries on the plastic consumed. Cheap PLA that I'm still dialing in. If I was trying to save plastic, I'd have killed the print early on. I don't have a 80mm fan yet, so the remaining item to proof is the diameter of the mounting hole for the fan.

Earthbound wrote:No worries on the plastic consumed. Cheap PLA that I'm still dialing in. If I was trying to save plastic, I'd have killed the print early on. I don't have a 80mm fan yet, so the remaining item to proof is the diameter of the mounting hole for the fan.

The fan SHOULD be perfect, as I got the dimensions directly off of the standard for 80mm fans. Thanks for being a test subject, though. I'll slow down my process a bit in the future.

redoverred wrote:The fan SHOULD be perfect, as I got the dimensions directly off of the standard for 80mm fans. Thanks for being a test subject, though. I'll slow down my process a bit in the future.

My advice and my request is this - Don't Slow Down. This amazing rapid prototyping capability is in part a collaborative effort. If you had waited until you printed one (after waiting for white ABS) it would be some number of days before the next cycle of improvement. Here it was a few hours. As long as the process is transparent, nobody is blind to the risks - here is an untested design, it will be updated as necessary, please provide feedback if you print/use it.

Earthbound wrote:

redoverred wrote:The fan SHOULD be perfect, as I got the dimensions directly off of the standard for 80mm fans. Thanks for being a test subject, though. I'll slow down my process a bit in the future.

My advice and my request is this - Don't Slow Down. This amazing rapid prototyping capability is in part a collaborative effort. If you had waited until you printed one (after waiting for white ABS) it would be some number of days before the next cycle of improvement. Here it was a few hours. As long as the process is transparent, nobody is blind to the risks - here is an untested design, it will be updated as necessary, please provide feedback if you print/use it.

Cool thought, I will totally do that then. From now on, I'll label them as "beta" first! Thanks for being cool!

I've printed two of these at 25% infill and they fit perfect with v1.2. I don't know if the fans will fit perfect, but at least the plate itself fits. I'll need to sand it to make it look nicer on the surface, but that's 3D printing eh?

I'm trying 1.2 at 10% infill with 3 perimeters. I flipped it over so it would print outer face down on the bed. Should be done shortly.

Yep, v1.2 fits like a charm. Now to get some 80mm fans.

Want to make a vented panel to replace the rear plexi? Needs to be a 90 degree curved plane (1/4 of a cylinder, outer diameter 141mm, inner diameter 139mm, 113mm tall). When installed, will be flexed to about 110 degrees, so the under-curved panel will hold with spring tension like the plexi did. I've been trying to do it in FreeCAD, but struggling to get some vent holes in the face. Holes should be in two clusters, away from center of arc (which is blocked by the tower). L/R plexi panels are similar (od 134.5 & id 132.5) if anyone wanted to make color matched pieces.

Earthbound wrote:Yep, v1.2 fits like a charm. Now to get some 80mm fans.

Want to make a vented panel to replace the rear plexi? Needs to be a 90 degree curved plane (1/4 of a cylinder, outer diameter 134.5mm, inner diameter 132.5mm, 113mm tall). When installed, will be flexed to about 110 degrees, so the under-curved panel will hold with spring tension like the plexi did. I've been trying to do it in FreeCAD, but struggling to get some vent holes in the face. Holes should be in two clusters, away from center of arc (which is blocked by the tower).

Yea, give me a few days to check it out and get back to ya. If you have any work you've done on it already, post it up somewhere so I can check it out. Sounds like a good idea to replace the slots on the top plate for ventilation since I want to block those off to build an enclosure.

Please note that I have updated the dimensions. When I did my test fit, I forgot that the rear panel was larger than the sides.

Earthbound wrote:Please note that I have updated the dimensions. When I did my test fit, I forgot that the rear panel was larger than the sides.

arc-two.skp

Can you post some screenshots with the dimensions shown on them? It seems I cannot open skp files in Inventor. I don't need many, I can pretty much figure it out, but just want to make sure I get it right :)

redoverred wrote:

Earthbound wrote:Please note that I have updated the dimensions. When I did my test fit, I forgot that the rear panel was larger than the sides.

arc-two.skp

Can you post some screenshots with the dimensions shown on them? It seems I cannot open skp files in Inventor. I don't need many, I can pretty much figure it out, but just want to make sure I get it right :)

Nevermind about the screenshots, I figured out what you were saying with the dimensions. Here is my first try at it. Let me know if you think the vents are too big/small, they should look different, etc. You can download the STL files below. I'm going to keep it off of Repables until it's mature. That being said, they're probably going to be a pain in the butt to print!

https://bitbucket.org/redoverred/replac ... s-for-rmv2

Started a thread for this here:

http://forum.seemecnc.com/viewtopic.php?f=35&t=6738

Thank you again for these. I shall modify them ot incorporate ducting. This way the electronics bay will get air from the outside.