Honeycomb Flow Straightener Mesh for 120mm Fan

A honeycomb mesh to be placed on top a 120mm square axial fan that converts most of the spinning, turbulent airflow into straight, somewhat laminar airflow.

I use gravity and friction fit to mount this on top of the fan for my DIY air filter , dramatically increasing output airflow upward and helping to circulate air in the room, which I hope helps to increase dust capture.

There is a 5mm gap between the fan output and the mesh as I find it reduces the turbulent noise greatly without a terribly large increase in print time.

I recommend printing with PETG as the screw hole spokes tend to break off with PLA, but if you can get good layer adhesion with PLA, or are careful when inserting and removing the mesh from the fan, then it is PLA is perfectly serviceable too.

Edit: The walls of the hexagonal mesh and edges are 0.9mm thick which is exactly 2 shells of 0.45mm extrusion. If you find the shells peeling apart, you will want to check your printer/profile's extrusion multiplier and increase it to 105-110%. A tell-tale sign you will have issues is if you see a visible gap between the hexagons on the second layer, adjust the extrusion multiplier until the gaps close up.

Print with the screw hole spokes facing up.