Modular Fan Blade Rotor Assembly

Received a fan from Amazon with a broken fan blade. They sent an entirely new fan so the 'old' one gave me an opportunity to design and print new fan blades. Attempts at a singular rotor and truly curved fan blades failed to mate properly. I moved to a modular rotor design that fit together like a puzzle. Then I settled on truly flat fan blades. The benefit was that all the components could sit flat on my print bed with minimal supports required. While the entire thing fits together like a puzzle I did use super glue to keep the fan blades from falling out. I ran out of blue filament mid-project so I continued with matte black. The materials are of different enough density that at the highest speed setting you can observe some wobble. The entire assembly is significantly heavier than the manufacturer's, but it works!  In the last picture it appears that there is another white fan blade on top of my print--that's the rotor retaining screw from the Amazon-brand fan.

Assembly Instructions:

1. Print five fan blades.
2. Print five pie tops.
3. Print five pie bottoms.
4. Print one rotor.  
5. Slide one pie top and one pie bottom together.
6. Insert the end of the fan blade into the slot on the pie top.
7. Repeat steps 5 & 6 four more times.
8. Mount the five pie and blade assemblies onto the central rotor.
9. Mount the finished Modular Fan Blade Rotor Assembly on the fan's motor's shaft.
10. Install the fan's stock retaining nut.
11. Reinstall the fan's protective cage.
12. Test the fan, SLOWLY increasing speed.

If you like this design then click here to check out my other uploads.  Happy printing!