80mm Fan Mod for 25G Thunderbolt NIC
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A 3D printable duct to add active air cooling to a cheap 25 Gbps Thunderbolt NIC
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I designed a fan duct to adapt an 80mm cooling fan to this 25 Gbps Thunderbolt NIC (which I learned about from this blog post).
Print it with the large side down, with organic supports for the narrower part that screws into the NIC's aluminum case.
Remove the blank side of the case and use the screws that came with it to mount this duct to the enclosure. Then screw an 80mm PC fan into the larger end of the duct. The design fits the Noctua NF-A8 80mm 5V fan perfectly. I used an NA-FC1 Fan Speed Controller to turn down the fan, so it is almost silent.
I bought these heatsinks (a single 2 pack) and stuck one on each side of the body of the NIC (making sure to remove the paper sticker that was on one side before doing so).
If you want to use internal power, instead of plugging the fan into a USB power source, you can solder to the two through-holes indicated in the picture where you see me soldering a fan connector. I secured the fan cable with kapton tape to the PCB for strain relief, and passed it through the cowling/duct while I was mounting it.
The final touch is an 80mm Noctua fan grill for airflow-optimized safety (don't want to cut your fingers on the fan blades!)
(Amazon links above are affiliate links, I earn from qualifying purchases.)