V4 AIR DUCT FAN 5015, 5020, ENDER 3 S1, S1 PRO, SPRITE EXTRUDER, ACCELEROMETER, LED STRIP

High-performance material ventilation system for Ender 3 S1 and S1 Pro (Sprite and Sprite Pro extruder), designed for a 5015 or 5020 radial fan with modular elements such as LED strip lighting or accelerometer attachment.

Test video on a 100 mm bridge link

This design only includes the parts that are in purple in the first image.

It is compatible with the original fairing (3010 hot end fan) and also with my design for the 4020/5015 hot end cooling fan and level sensor relocation.

You can find this design on this link

V4 design features:

The V4 design uses a 2 duct architecture (now also single duct option) of ventilation with a fan in the axis of the nozzle which allows for a very direct flow due to the low slope and more concentrated air pressure outside the fan housing.

The dual-duct architecture allows good visibility of the print on the front and more clearance with the tray as well as around the hot end to allow for a larger hot end kit to be mounted such as the Creality high flow.

It is not the replacement or an upgrade of the V3 design but a design and architecture variant with the same function.

The V4 design is just as effective as the V3 (with a small advantage noticed in my very high speed testing on overhanging perimeters).

You can find the V3 design variant on this link

The design is designed in multiple pieces so that it is easy to print and avoid brackets, and it is adjustable in height to fit your nozzle. Place the bottom of the two-vent duct (Duct V4) about 3mm above the nozzle/plate and 2mm for the one-vent duct (Duct V4 Single).

If you line up the top of the center plate with the top of the extruder motor it should give you this clearance.

Go for a 24v fan like the stock one to avoid voltage changes and good quality fans.

The added weight compared to the original parts (4010 radial fan and stainless steel shrouds) is +16 grams With the 5015 fan and assembly screws (without LED bracket and accelerometer).

Print:

You need to have your printer properly calibrated for flow as well as dimensional accuracy so that everything fits together properly. Especially for the fan support that fits on the center plate without screws. Positioning the parts on the plate according to the photos, there is no need for a support if your printer is able to handle bridges and overhangs.

Use the back of your PEI plate (smooth part), glass bed... or any other type of tray with a smooth surface to get a nice flat part which will make mounting easier.

5015 or 5020:

Which fan to choose between the 5015 and the 5020 radial? Both have different advantages.

Between my Sunon 5015 and my GDSTime 5020, the 5015 is better at cooling, but it's a bit noisier (it has a higher RPM) than the 5020.

In summary, if you are looking for maximum efficiency, use a 5015. If you are not significantly increasing your print speeds and want a quieter fan, use a 5020.

Assembly:

On the top of the center plate a sanding may be necessary so that the contact surface is flat and tight when assembled. If you do this you will not have any leaks. You also have the option of gluing the pieces together.

Screws for mounting the fan :

• 1x screw M3 20 mm (fan holder 5015 version without nut) or screw M3 25 mm + nut M3 (version 5015 with nut) or screw 25 mm with or without nut M3 (for fan 5020), screw the screw must be inserted from the left of the holder

• 2x M3 screws 16 mm (holds the parts together)

• 2x M3 8 mm screws (fixing to the extruder)

• Optional 2x M3 nuts or 2x threaded inserts to be heated (holds parts together)

• Optional 2x M3 screws 6 to 8 mm (depending on your accelerometer, if necessary place washers)

• Optional 1x M3 screw 5 mm (LED strip holder)

Holder for accelerometer:

Designed to mount an accelerometer such as ADLX345, Creality Sonic Pad or USB model such as KUSBA or FYSTEC.

Screw the accelerometer first on the bracket with two screws. If the screws protrude a little bit (maximum 1.8 mm) it is even better because they will allow to make a support against the extruder motor.

Then screw the support on the printer by replacing the 8 mm screw on the top of the central plate by a 10 mm screw.

LED strip holder:

It is designed for 42x13mm or smaller LED strip.

I used a 24V LED strip that I plugged directly into the printer's power supply through the printhead cable sheath. I also added a small toggle switch so I could turn off the LED strip.

Otherwise you can use this kind of LED already provided for that link

*Thanks to Kingsidorak for his modeling of the extruder.

PETG or other heat resistant filament

0.4 mm nozzle

Layer thickness 0.16 mm or less

Filling 20% or more

No supports