CORE One Exhaust Fan Cover

There are so many design decisions I really like about the 🥰 CORE One. But when it comes to the exhaust fan grid, it's just on the edge to call it "functional" 😟. So I felt I needed to design a drop-in replacement to fix the things I did not like.

What's wrong with the original?

• Breaks easily - Seriously, this thing is fragile and will snap if you look at it from a wrong angle
• Tight clearances - M3 screws get quite close to the belts, and the same is true for the cable tie
• … and a Thermistor that is a bit dangling around

That are the changes

• Cable management - Improved cable management to keep your wires neat and where they belong
• Improved clearances - Using Button Head Screws and the reworked cable management keeps things away from the belts
• Thermistor mount - Securely position the thermistor where it needs to be
• Aesthetics and stability - Clean and sturdy design that your CORE One deserves. Of course with snap-in mesh inserts that can be printed in accent color ... and what else should this be than Prusa Orange 😎.

How to build it

1. Choose your variant:

There are two variants for the thermistor mount: One uses a M3x5x4 Heat Set Insert, and the other just screws into plastic. I recommend to use the Heat Set Insert one as it makes the assembly just a little easier. But the other will work perfectly fine, just be a bit careful not to bend the part when assembling. Do not hold it at the tip, but only on the round top.

Two variants for the mesh inserts: Standard should be the 0-10 variant (with a 0.10mm tolerance) which should provide a snap-in experience. But if you have any issues, use the 0-15 variant (with 0.15 tolerance).

2. And then just follow the pics:

Print Settings

👉  Important: Seam Positioning  👈 The thermistor mount mechanism will be sturdy but make sure the slicer does not position the seam in that specific area. Avoid the parts marked red, and it does not hurt to enforce the seam on the inside where it's marked green.

For the print settings, there is not really anything specific to know. Here is what I used:

• Filament: Prusament PC-CF to match the interior and ASA for the accent parts
• Layer Height: 0.2
• Extrusion Width: 0.4
• Perimeters: 4
• Top / Bottom Layers: 5
• Infill: 40 %
• Support: No

BOM

• M3x30mm Button Head Screw ISO 7380 (4x)
  Technically, also the original SHC screws will work but using BHC will give you 1mm more clearance to the belts and also the recess on the top surface is designed for the slightly larger BHC heads.
• M3x6mm or M3x8mm Socket Head Screw (1x) 
• Optional:
  • M3x5x4mm Heat Set Insert (1x)

CAD

As usual there is the native Fusion file in the files section with the complete project timeline. Feel free to mod it, place a logo on the mesh inserts, create your own thermistor mount…. 
Just don't forget to leave a 💛 Like in case you like the model.