I didn't have much of a need for a fan duct, but after removing my original plate steel duct I was surprised by how much it weighed. I decided to kill two birds with one stone and make a new fan duct that was more effective and lighter weight than the original.

This modification is a direct swap for the original, and will use the same fan, even if you're short on cable length.

I've also included a 0.4mm spacer in case you want to drop it down a bit. Stock should have a couple of millimetres clearance from the printbed and because the duct is directed downwards slightly this is fine.

Results are remarkably good. See the test print comparison. The rubbish one is the normal vent. In fact, these results were so good I'm wondering if my cooling fan was misbehaving in the rubbish print (same gcode for both prints).

The existing screws may be a tight fit. You may have to run a 2.5mm drill bit through the holes first. I decided I'd rather have them too tight than too loose.

Print Settings

Printer Brand:

Wanhao

Printer:

Rafts:

No

Supports:

Resolution:

0.2

Infill:

Notes:

Print it with the fan position downwards. This puts most of the support into the main chamber where it's easy to remove. I'd also recommend printing it with a high temp plastic as it's near the heater.