Smart Orbiter v3.0 Tool head for Ender 3 v2 with detachable fan duct + CR-Touch Mount

This is a complete mounting solution if you wish to use the Smart Orbiter v3.0 on an Ender 3 v2 while keeping noise down by replacing the Orbiter's fan with a Noctua NF-A4x20. Additionally, you can mount a 5015 blower fan and CR-Touch Probe.

Parts needed:

• 3D printed parts (adapter plate back, Fan + CR-Touch Mount, drill guide, fan duct, limit switch trigger)
• 6x M3 Heat set insert
• 4x self-tapping fan screw (included with the Noctua fan)
• 4x 3 mm o-ring (or similar spacer)
• 9x M3 x 8 mm pan head screw (some can be longer, I got by using only screws leftover from the old hotend and extruder)
• 2x M3 x 8 mm countersunk screw (ideally not much longer)
• 2x M3 x 20 mm pan head screw (can be slightly longer)
• 2x M3 x 5 mm pan head screw (also not much longer)
• M3 washers (use where necessary)

Preparation:

• Using the drill guide, drill holes 1 (M3 clearance, 3.5 mm) and 2 (M3 tapped, 2.5 mm) in the carriage and tap the latter one M3.

• Melt some M3 heat set inserts into the holes marked in red on the adapter plate and the fan + CR-Touch mounting plate.

• Insert some 5 mm x 3 mm magnets into the yellow-marked holes in the fan plate, as well as into all the holes in the fan duct (make sure to have opposite poles on the outside, so the duct will stick to the plate later).
• Remove the stock fan from the Orbiter.

Installation:

• Temporarily unscrew the stepper motor from the Smart Orbiter (necessary to access all the screw holes).
• Attach the Orbiter to the adapter plate from the back using M3 x 8 mm screws (marked above in blue). Make sure the screw heads sit flush with the back of the printed part.
• Now screw the adapter plate to the carriage using three (green) screws from the front and two (red) screws from the back. Ensure these (especially the ones from the back) are not too long (see note in parts list above).
• Reattach the stepper to the Orbiter.
• Glue the limit switch trigger to the back of the adapter plate, so it butts up against the carriage and sticks ~ 9 mm out on the left side.
• Use two M3 x 10 mm countersunk screws to attach the fan mount to the two screw holes in the front of the Orbiter body.
• Secure the 40 mm fan in between the two plates using some self-tapping fan screws.
• Attach the 5015 blower using two M3 x 20 mm screwed into the heat set inserts. Ensure there is a small gap (~ 1 mm) between the fan and the plate. I used some rubber o-rings.
• Attach the CR-Touch mounting bracket to the other two heat set inserts using M3 x 5 mm screws. You may have to adjust this up/down slightly depending on your nozzle height.
• Attach the CR-Touch to it's mount as usual (again, I added some o-rings to dampen any vibrations and to move the probe down slightly).
• Snap the fan duct into place.
• That's it, happy printing!

NOTE: If anything about the assembly is unclear, please refer to the exploded view (last picture) or the Onshape CAD document linked below. Using the toolbar on the bottom, you can also access the exploded view there.

Onshape Link: https://cad.onshape.com/documents/cf18b40bc5020a8cfd4fda3c/w/cc7b5febff21b201a62e8464/e/0e4aad386c9602f4d9509142 

Printing:

All parts were printed in PLA. The two plates were printed at 0.2 mm layer height, the fan duct was printed at 0.15 mm layer height laying on the side facing away from the fan (see pictures).