CPAP Muffler System - C.M.S

No CMS in use;

Only the outlet muffler box, with a small impact of the motor muffler box;

And the full CMS in use;

This was designed after watching Andrew46 present a truly awesome design for a muffler system for the CPAP motors, that cools filament really well. But is really noisy if left in an open space at full blast.

I have now fully tested this design as of 07/12-24 CEST 23:16

It's not 100% complete yet, but perhaps 90-95% from what I can tell.
There are no issues that will cause catastrophic failure of any sort, just QoL things.


Most of the parts are printed in whatever stiff and strong material you usually run.
But there are certain parts that are specifically made for TPU, I have used 3D Prima TPU with a shore hardness of 95A, 1 wall and 15% gyroid infill also no “Alternate Extra Wall”.


General print settings anyone should use, at least;
4 wall minimum, can be used for all parts.
4 top and bottom “walls” as well.
35% infill, I personally like Gyroid. One can argue acuostically that one infill works better than another. But there are really no gains to investigate such for this, better to fill the inside with sand then or something else “deadening” then.




This 3D model project does not require any special tools or hardware, apart from M3 threaded inserts and whatever M3 bolts you have or think should work best.
Also sound dampening material is required for this to work fully, melamine foam is a cheap and nice option for this.

I have designed the thread insert holes after the Tapex Thread inserts, I find this to have the best grip.
https://www.tappex.co.uk/products/brass-threaded-inserts/multisert/?type=single-thickness-head&thread=M3&length=4.1&extras=large#selector
 

Velocity comparison tables

The velocities are not an average out of X amount of tests, but the max out of one test per set of values.

I drilled the Tentacool's holes up by quite a bit, for all holes in the part.
Much better flow compared to the stock one.

Improvment of the C.M.S is required, as well as getting a better hose!

My WS7040 with the driverboard, not the "turbo board" though, had these Klipper settings. So you can assess what the percentage really is, in terms of impeller rotation;
> max_power: 0.82
> cycle_time: 0.005
> off_below: 0.16
 

UPDATE 07/12-24;
Uploaded v0.6, I have now printed all the parts myself as they should be. So made necessary alterations to the model, to make it easier to print & assemble and work as it should.
There is now a OrcaSlicer project uploaded besides the previous step and f3z files.

I have yet to test the system out, as I am currently going over any missed thing, if there are any. Also need to get a hold of the sound dampening material.
Also test fit TPU parts with WS7040 and add heat inserts to the parts that need it.

Next update might include more detailed info on what to do to make this work, mechanically at least.
Then after that, make some stable klipper firmware suggestions for implementation perhaps, as well as OrcaSlicer settings to use. We'll see what happens.


UPDATE 07/12-24---PS;

• Fixed misaligned bolt holes in the Dual lid model.
• Added support structures to the Outlet Muffler Box, to support two of the 3 connectors better when pulling them out.
• Altered on of the TPU supports mounting cutout, so it would be easier to insert the support in the Motor Box.
• Made the Motor Outlet Gasket to wrap around the outlet even more, also forcing the motor out 2mm to the other side of the box. To make it have equal distance to the wall from all sides.
• Shortened the length of the thin motor support TPU part.
• Fixed badly supported threaded insert holes in the Outlet Muffler Box.
• Altered the visible lid surface layout, to include text and some line graphics, for stylized purposes.