CPAP Turbine Voron Mount Prototype - Resmed S10/S9

had access to old used Resmed Airsense s10 CPAP machines that I tore apart to get to the turbine.

Turns out they are these compact cylinder units which I have not seen any mounting mechanism for.  It is a 3 phase without hall effect, but still seems quite powerful, though documentation is scarce on a part that has no part number documented. I included screenshots of what I could find.

So I designed one of my own, if rudimentary, mounting hardware.  I would recommend only salvaging these motors from an existing dead unit instead of purchasing them, as they seem quite expensive as stand alone parts for purchase.  Check out iFixit for disassembly info:

https://www.ifixit.com/Guide/ResMed+AirSense+10+Pump+Motor+Replacement/137050

The turbine is encased in a plastic shell, and a blue silicone sock.  The shell was too oddly shaped and no practial mount points.  The sock was also oddly shaped, but I figured some areas of its shape would still contribute to mounting the turbine, with the added benefit of being a shock absorber.  I trimmed either end off the sock as the extended shapes were not useful.

I created a shell that can clamp around the turbine and the silicone sock alone will provide plenty of grip to keep it from moving.I had to include a small notch in the side, to allow the wire retainer space to stick out without getting crushed.

I used the lessons I learned in my first attempt to design an enclosure:

https://www.printables.com/model/892331-3d-printer-cpap-turbine-general-mount-prototype-re

I used a similar shell design and added a funnel/scoop shape to channel air from inside the enclosure.

This should help with support for cooling when printing ABS, since outside cool air would be detrimental to the part.  I have yet to print ABS with this setup, but I am confident it should be doable since there is decent control over the speed.

All M3 holes on the chamber body require M3 5x4 heat inserts, four for the shell attachment and four for the brackets that attach inside the intake area.  The outer shell can be attached by four M3 8mm bolts.

The main body and spacer are attached to the top of the frame by M5 bolts.

I also did not bother with with a notch for wires in this version, as I looped the wires around the blue silicone sock inside the unit, and thus acts as a natural strain relief.  This is given that the wires go down only.

The filter ended up being flat across the intake section, as I did not want to protrude out too very much into the enclosure.

The spacer sandwiches between the main body and the filter bracket.  This accounts for the thickness of a 3mm of panel, and 1mm of foam tape.  This can be resized as needed.  It also helps retain the filter and acts as a top and side brace for the CPAP hose.

The inner bracket is screwed in by M3 bolts 10-12mm through the spacer into the main body intake.

The inner bracket also braces against the back panel, spacer and main body in order to wedge the CPAP hose in securely.  The bottom two bolts may experience a lot of leverage if the main body is pulled away from the panel, so be careful.  Additional bolt mount points may be needed along the bottom of the assembly to prevent the heat inserts from pulling out but I don't have a design for that yet.

As noted in my previous model:

Some kind of filter is Strongly recommended.  This turbine cannot be disassembled for maintenance.

I found that the turbine performed well and is very manageable. When linked with a BLDC controller and the PWM signal from a servo pin, I could run the motor from 2%-100% without issue.  Only at 1% it would stall which is quite impressive.  Since the turbine was basically free, not a bad outcome.

Again, it is not pretty or elegant, but it works.  I didn't get a lot of good photos during assembly, but I will try to improve that later.  I have uploaded the STEP file for further tinkering.

Strongly suggest printing in ABS.