Parametric Ducts: Mammoth Series V1

I am a product design student interested in parametric design, which I have been exploring over the past year. Recently, I decided to apply this approach to upgrading my 3D printer’s fan duct. My Ender3V3SE printer was originally stock and struggled with cooling the plastic at higher speeds. To address this, I initially printed a side mount from Printables. Now, I am looking to upgrade to a 5015 fan; however, I found limited options available for my specific needs.

As a solution, I designed a two-piece system consisting of a mount and a duct, allowing me to test prints efficiently without having to disassemble the entire setup. The most interesting aspect of this project was developing the duct entirely through parametric modeling in Grasshopper.

This picture shows the two-part assembly with all the necessary screws: two screws that came with the printer, which secure the part in place, along with two M2 screws, two washers, and two nuts.

You'll need to clip the old 5015 2-pin connector and solder the new, smaller 2-pin connector that fits into the printer, using heat shrink with solder seal for a secure connection.

Make sure that when you strip the wires, you create a strong mechanical bond between them by twisting them together securely before soldering. This ensures better conductivity and a more durable connection.

The first step in the assembly process is to securely fasten the mount, as shown in the pictures.

The second part connects the mount and the duct using an M2 screw, a washer, and a nut in each hole.

Ensure that the clearance is properly set. If it is not, there is a possibility that the nuts have not been tightened securely enough.

And now it comes the boring part of how did we got here for those interested

After numerous iterations marked by trial and error, I ultimately developed a more stable version. The components were produced using resin printing, and for those without access to such equipment, I also achieved moderate success with 3D printing.

This is a visualization of the project in Rhino 8, a CAD software.

Also the model of the printer was used by https://www.printables.com/model/672045-open-source-ender-3-v3-se-reference-models-step-fi I solely used the model as a reference, without incorporating any of its elements. Nonetheless, I extend my gratitude to the creator, whose work spared me the time and effort of calibrating the printer.

This is the parametric aspect of the project. Parametric design in this application enables real-time modifications—adjusting a single point on the XYZ axis instantly alters the final outcome. This flexibility allows for the rapid creation of multiple prototypes, simply by tweaking a dial, showcasing the true power of parametric design

Each point is strategically placed to guide the curve, ultimately shaping the airflow within the duct. Numerous possibilities were explored, from attack angles to duct diameters and proportional ratios. This marks Version 1 of the Mammoth series, inspired by the distinctive form of the ducts, as astutely observed by:

(https://www.reddit.com/r/Ender3V3SE/comments/1it701v/comment/mdnd9px/?utm_source=share&utm_medium=web3x&utm_name=web3xcss&utm_term=1&utm_content=share_button)

I would greatly appreciate any feedback and constructive criticism. As this is my first project in this field, I found the design process both enjoyable and enlightening, gaining valuable insights along the way. The core objective of this project is to continuously refine and enhance duct designs while minimizing complexity. Future iterations will allow for seamless attachment to the mount, ensuring effortless upgrades without unnecessary hassle.

UPDATE 14/4/2025

Due to vibration issues I experienced personally and also reported by a user, I added two pins to secure the fan in place. My first test was a success, and I hope this has resolved the issue.