Ender 5 S1 Cooling - Dual 5015 + 4020 + Zero Y Offset (NBR Remix)

My modified version of NBR's Ender 5 S1 cooling setup ('El Pablo').

This is to suit the mods I'm currently running including dual 5015 part cooling fans, a 4020 for hotend cooling and NF Mellow hotend. It also greatly improves the bed levelling as the Y offset has been reduced to 0.

I've made the following changes (that I can remember):

• Replaced the hotend cooling fan's cut out
  • Improved airflow
  • Reduced noise
  • Works with aftermarket hotends with lower height heatsinks
    • I'm running this with a Sunon 4020 24v Maglev
• Vents
  • Slight change in height for improved hot end and CR touch clearances with my setup
  • Increased angle of the vent outlets
  • Reduced length to give more clearance to aftermarket hotend heater blocks
    • I'm currently running this with a NF Mellow but have also tried the Micro Swiss ‘all metal for CR10’ and 2x Sunon Maglev 24v 5015 Fans
• CR Touch mounting (zero Y offset)
  • Decreased height to align with my hotend (NF Mellow)
  • Added cutout for the cable and connector
• Added loop for fan cabling to route though

I'm using this in conjunction with my hotend adapter bracket - and my EBB36 CAN Bus board mounting.

Note: I'm new to CAD / 3D modelling so I'm sure a lot of my changes could be improved on further or done in far more efficient ways - but it's working for me.

Things I'd like to make further changes to

• Add a mount for a nozzle / endoscope cam.
• Make the vents and CR touch detachable so you can have various height hot ends, and make printing quicker.
• Make changes to reduce the amount of supports required for printing.
• Support angled 4020 fans for the hot end.
• Stronger vent tips might be nice.

Printing

As far as printing it, I've printed many of these all of them on a 0.6mm nozzle at either 0.24 or 0.2 (better for the vents) lay height in both PLA and PETG (either seems fine).

• Infill: 25-40% (cubic or cubic adaptive seems fine)
• Filament: PETG or PLA (_not_ silk though!)
• Supports:
  • Yes, unfortunately (It would be nice to make the vents detachable at some point to avoid some of this).
  • Auto supports for angles more than 45deg.
  • On build plate only.
  • I also paint a couple of extra supports higher up the fans (see screenshot) to increase stability during printing.

It takes about 3 - 3.5 hours to print on the Ender 5 S1 at 75-140mm/s for a draft print, then you can go slower for your final print.

Goes without saying - but YMMV, the design is for the mods I'm running - but probably should be fine for other hot ends / fans etc…

Remix

This is a remix of NathanBuildsRobots (aka ‘NBR’) cooling as seen in the following video.

While Printables wouldn't let me select the option to mark it as a remix as the original is not on Printables - I checked and have Nathan's approval to share my remix here.

If you remix this, please link to NBR's YouTube as the initial design credit should go to him.

If you want to download the original model you can subscribe to NBR's Patreon for just $1USD/month here.

Go give his channel a follow!

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Updates 2023-05-17 (v44-b):

• Lowered height of the hotend cooling fan.
• Removed right side cable tidy, it just looked a bit dorky - the old model with it is still there if you want it.
• Improved strengthening on the cross-member and left gantry fixing.