Improved fan duct for Creality CR-10

Improved fan duct and part cooling fan mount for the Creality CR-10.

This design works with the stock fans and screws, no additional hardware needed and no modifications to the cabling. There is no need to move or even touch the hot end, it can stay in it's original position.

I was having trouble with failed prints due to clogging in the hotend caused by poor cooling. The design of the stock fan duct is far from optimal but works well with the powerful stock fan, not so much with a Noctua fan that has lower air flow. The main problem is that a lot of air leaks out at the bottom of the stock duct

This design forces almost all the air to flow across the hot end. It also directs the exhaust in a way that minimize the losses by having a large channel after the cooling fins.

There is clearance and a small cooling air flow around the hotend and the fan duct to make sure the plastic fan duct does not overheat.

The part cooling fan is mounted on the sloped end and directs the cooling airflow directly towards the nozzle. The cooling works surprisingly well without any extra ducts, but I have included a part cooling duct as well that improves the print quality.

The fan duct looks massive but with 3 perimeters and 10% infill it weighs less than half of the stock metal duct.

I mounted the fans by screwing directly into the printed holes, no drills or tap required. (results may vary)

I realize that this is a fairly boring design and not as cool as the various fang models or the light weight variants, but it works and well and that was my main design goal.

EDIT:

Added a part cooling duct to the files. It's also a separate thing with instructions. https://www.thingiverse.com/thing:3276802

Print Settings

Supports: Yes

Infill: 10%