NextGen Enclosure Exhaust Fan Adapter

I'm continuing to modify my NextGen enclosure, so it works for the space and setup I have.   The TPU helps with the seal and vibrations for the fan.  If you don't have TPU, you can try skipping those parts, but I recommend adding them.

R2 parts have resolved the minor air leaks when using the fan for me.  If you are experiencing any issue with this design, please let me know.  I make improvements and revisions as I use them.

How this project started:

After researching VOCs I'm still more comfortable exhausting them out of the house when dealing with things like ABS.  I do have a really good air filter with a carbon filter, plus HEPA/carbon scrubbers inside the enclosure.

Parts List: 

120mm Fan with Speed Controller:

• https://www.amazon.com/dp/B09D9F2MVB?ref=ppx_yo2ov_dt_b_product_details&th=1
• You could install any 120mm fan (AC/DC 4 pin, 3 pin, integrate into the enclosure controls, etc).

4 inch flexible hose with clamps:

• https://www.amazon.com/dp/B07WRDTX4C?psc=1&ref=ppx_yo2ov_dt_b_product_details
• Or any of your choosing.

NOTE: I'm working on a modification for the side vents that I designed where you can remove the whole fan assembly -  Next Gen Enclosure Side Vent by AKA | Download free STL model | Printables.com

STL File Naming:

Parts are named after material recommended for printing and quantity you should print (ex: TPU_Fan_Gasket_X2 print in TPU and a quantity of two).

Print Settings:

• Default PrusaSlicer settings for both TPU and PETG @ 0.20mm quality.
• Additional instructions for PETG_Fan_Exhaust_Adapter_Bracket_X1:
  • Under Print Settings change the Bridge Angle to 45 degrees.  PETG does not like long bridges.  The overhang will come out cleaner and the built-in support easier to remove.

Assembly (use the cover picture for reference):

1. Place TPU_Enclosre_Gasket_X1 on the external surface of the enclosure where you are mounting the fan (if on the side use something easy to remove like blue painters' tape to help hold it in place.
2. Place the PETG_Enclosure_Fan_Mount_X1 over TPU_Enclosre_Gasket_X1.  The insets for the nuts should be facing towards the inside of the enclosure.
3. Place one of the two TPU_Fan_Gasket_X2 on the PETG_Enclosure_Fan_Mount_X1.
4. Position the fan on top of the TPU_Fan_Gasket_X2.  The air flow direction should be pulling air from inside the enclosure to outside.
5. Place the second TPU_Fan_Gasket_X2 on top of the fan.
6. *Place the PETG_Fan_Exhaust_Adapter_Bracket_X1 on top of the TPU_Fan_Gasket_X2.
7. Insert the screws that came with the fan.
8. Attached the nut to the back of the screw going through the entire assembly on the inside of the enclosure.
9. Once tightened, remove the two built in support on either side of the PETG_Fan_Exhaust_Adapter_Bracket_X1.  This will expose the two groves that the PETG_Exhaust_4inch_Hose_Adapter_X1 and PETG_Exhaust_Port_Cover_X1 slide into place on.
10. Attach the 4 inch hose with clamp to the PETG_Exhaust_4inch_Hose_Adapter_X1.
11. Now you can either close off the enclosure, or attach the pipe and vent into a filter, or out of the room.

*R2 Parts:

• 6. Place TPU_Inner_Seal_R2_X1 inside PETG_Fan_Exhaust_Adapter_Bracket_R2_X1 with the higher side of the seal facing the front and back.
• 6a. Place this assembly on top of the TPU_Fan_Gasket_X2.

Change Log:

• 05-13-2022
  • Added guard to PETG_Enclosure_Fan_Mount_X1.stl
• 05-16-2022
  • Added updated picture of PETG_Enclosure_Fan_Mount_X1.stl showing.
• 05-17-2022
  • Added picture/example of fan strength at full speed using a normal tissue.
• 06-05-2022
  • Added stronger PETG_Fan_Exhaust_Adapter_Bracket_R2_X1 and TPU_Inner_Seal_R2_X1 to resolve small airflow leak.
  • Added ‘TOP’ to PETG_Enclosure_Fan_Mount_X1 for clarity.
• 10-31-2022
  • Updated PETG_Exhaust_Port_Cover_X1 with a revision 2 to better fit the new PETG_Fan_Exhaust_Adapter_Bracket_R2_X1.  Beveled leading edge to simplify slotting into the track.
• 11-03-2022
  • Added R2 of the PETG_Exhaust_4inch_Hose_Adapter_R2_X1, slightly shorter, beveled leading edge to simplify slotting into the track.

Additional Models:

• 4 inch hose adapter to 5 inch AC window vent by AKA | Download free STL model | Printables.com
• Added an activated carbon/filter module for PLA/PETG when needed that slides on top when not needing to vent outside a window:
  • Exhaust Fan Filter Module by AKA | Download free STL model | Printables.com

Tinkercad Fan model I borrowed for the assembly graphic (find the secret message):

https://www.tinkercad.com/things/6tWCJeqnI6l