3D Printer Cooling Fan Settings: Best Practices for Every Printer

fan 3d print

Introduction

You may have wondered why your prints are warped or have poor quality surfaces. Chances are, it has to do with your 3D printer cooling fan settings. In fact, cooling fans matter even in the 3D printing stage, as they will influence the quality of the print as well as the speed and efficiency of the process.
Finding the perfect fan settings on the other hand is not a simple task. One size does not fit all. The cooling strategies employed can vary between printers, filaments and even individual models. Therefore, moving from a mediocre level to higher quality prints requires some understanding of your 3D printer cooling fan.
In this manual, we’ll cover the basics of the 3D printer cooling fan’s operation and its potential optimization techniques. This information will prove useful to beginners learning the ropes and experts working on their setups. So, let us get started and solve the puzzle of cooling fan settings of a 3D printer together.

Let’s Develop a Deeper Understanding of 3D Printer Cooling Fans

Cooling fans are a critical component of 3D printers. It would be very difficult to imagine a printer that doesn’t deploy fans for cooling. You can think of it as air conditioning for your prints. It provides the right environment so that everything turns out okay. But what is the role of the 3D printer cooling fan?
The 3D printer cooling fan’s main purpose is to cool the recently laid down plastic as fast as possible. This rapid cooling serves a few purposes. To begin with, it helps avoid warping and curling in materials like PLA which shrink due to temperature changes. Without appropriate cooling, your prints would end up being as crooked.
In addition, this type of cooling significantly enhances cooling efficiency.
Effective cooling lets the printing process easier as there is no need for support when the object can be printed horizontally, sharp edges can be achieved along with smooth surfaces. In a study done by Journal of Manufacturing processes, proper cooling was said to minimize surface roughness by as much as 37%. It explains the difference between a poorly done print and a professionally crafted one.

Applications of 3D Printers

The use of a 3D printer is seeing an increasement in areal coverage, opening up new possibilities for what can be done. 3D printing or additive manufacturing is changing the way things are made, enabling new and more efficient methods of production in the aerospace, automotive and healthcare sectors. To cite an example, the medical field is being transformed by the rapid manufacture of personalized prosthetic limbs and dentures.
As the field expands there is a growing need for development for more complex solutions such as printer accessories which includes cooling fans. Cooling systems are designed to provide the necessary cooling for the components of the 3D printer which, if not done, would result in substandard prints, deformation of prints, or unwanted strands of filament being produced from the nozzle. Furthermore, 3D Printing technology is widely used for making models and prototypes in educational and architectural activities which means that more advanced cooling solutions are necessary to achieve the fine details and precision that is needed. In general, the advancement and dependability of 3D Printing in sectors will always be directly proportional to the cooling sysstems efficiency and dependability.

Why Cooling Fans Matter for Print Quality and Efficiency

Cooling fans affect the overall print structure and their details. Good cooling performance is crucial to the prints as too much cooling or too slow cooling can lead deformation. Layering prints at slow cooling temperatures can cause over sagging while over aggressive cooling can lead to gaps in the prints, making them vulnerable to breakage along the layer lines.
Cooling does not only affect the quality but also the effectiveness of the cooling fans which remains highly important. When proper cooling is employed, higher printing speeds with good quality prints become achievable. Lower temperatures on the previous layer help keep the printer stable and allows him to quickly shift to the next layers. The stability of the print is maintained allowing cooling systems to increase print speed by nearly thirty percent in advanced systems.

How Cooling Fans Improve Print Speed and Efficiency

Is printing faster achievable with only a single fan? In fact, the answer is yes! The primary purpose of 3D printer cooling fans is not just quality enhancement but also crucial components for increasing printing speed and productivity.
3d printer fan duct design
When you print, there is the inflow of different parts. First, When the first layer is complete, the machine has to waits for the previous layer to cool down, proper solidification must occur before moving onto the next layer. Because of a powerful 3D printer cooling fan, the machine is able to advance quicker. Now, because a fan is present, cooling of each layer becomes easier and enables the former printer to turn to the next layer.
But, adjusting the working fan is not the only aspect that comes into play when using a 3D printer. Balancing airspeed and cooling fans is one of the challenging aspects to form effective layout while printing. Finding the intersection between detail and sagging can be tough, Too much cooling air can separate the layers, On the other hand, lack of cooling can result in warped detail. If all of that measurment is constructed into a precise balance, reasonable print quality can be achieved with lowered print durations.

Cooling Fans vs. Print Speed: Finding the Right Balance

A great misconception is that when printing faster, the quality of the print is compromised. Often, with the correct cooling settings, you can increase print speed without worrying about quality. As a matter of fact, for some materials like PLA, precise cooling while eco-printing enhances quality since the layers do not have sufficient time to distort under pressure.
To ensure good quality print, check the default fan settings first. Many of the printers come with very conservative settings by default. Increase the fan speed and print speed incrementally and check the results. You may even consider yourself lucky seeing how much print speed you can actually achieve while getting good quality prints.

Optimizing Cooling to Increase Printing Efficiency

Your cooling setup does not have to be limited to adjusting fan speeds only. Consider the following tips to enhance the performance of your 3D printer cooling fan:
  1. Improve the design of your fan duct. The airflow around your print can be considerably improved by a well-designed fan duct. There are plenty of 3D printer fan duct upgrades, many of which are designed to be printed by the user.
  2. For many printers it might make sense to replace the stock fan with a 3D printer blower fan, as this can result in more directed and stronger airflow.
  3. As a starting point, you may consider using different cooling strategies for different materials; while PLA typically requires maximum cooling, ABS often has minimal or no part cooling requirements.
  4. While it does not directly cool the print, it is important to take care of your 3D printer hotend fan as well. An effective hotend fan allows for more consistent extrusion at higher print speeds by reducing heat stagnation, which aids in preventing heat creep.
It’s not uncommon to see efficiency gains of 20-30% or more with optimized cooling. By fine tuning your cooling setup, you can reduce print times without sacrificing quality.

Types of Cooling Fans Used in 3D Printers

3D printer fans differ based on certain characteristics. Knowing the different types and functions of fans will assist you in setting up your printer. For the sake of clarity, they can be put in two broad classes: their purpose, and the form they take.

Layer Fans & Hotend Fans

Initially, fans can be categorized as either layer fans or hotend fans based on the roles they play while the 3D printer is working:
  1. Layer Fans (Part Cooling Fans): These are the workhorses of print cooling. They’re responsible for cooling the plastic as it’s extruded, helping it solidify quickly. A good layer fan setup is crucial for achieving sharp details, successful bridging, and preventing sagging in overhangs.
  2. Hotend Fans: While not directly cooling your print, these fans are vital for maintaining consistent extrusion temperatures. They prevent heat from creeping up the hotend, which can cause filament to soften prematurely and lead to clogs. Think of the hotend fan as the radiator fan in your car – it keeps the engine (or in this case, the hotend) from overheating.

3d printer fan

 

Axial & Radial Fans

  1. Axial Fans: For axial Fans, the rotor is responsible for the blade rotation and the motor is located on the axis of rotation. The blades direct airflow parallel to the axis of rotation, which results in a smooth and constant air stream.
      Usually, they are powered by an AC (Alternating Current) or by a brushless permanent magnet direct current motor (BLDC). Such motors proved to be powerful, efficient and low maintenance, operating at constant speeds. Due to their simple design, these fans can be used in various general cooling applications, such as cooling the print area of 3D printers. Because of their moderate pressure output, they excel in displacing large volumes of air in large volume spaces, but not in crowded ones, where they cannot push air through.
  2. Radial Fans (Blower Fans): Radial fans employ a motor to turn an impeller inside the casing. The high speed rotation of the impeller causes air to be sucked in from the center and then pushed outwards, which creates airflow at high pressure between the housing and rotor. Blades without hubs are a common way of engineering radial fans too, which operate purely based on the principle of centrifugal force, air is pulled in through the middle and exhausted from the periphery of the impeller.
      For many fan designs, brushless DC motors are used as power sources, while the fans themselves may differ in rotational and hence operational speeds. Radial fans have some edge over other fan types in focused cooling situations where the hot end or part that requires cooling has to be under higher pressure in order to receive precise air flow.
Here’s a quick comparison:
Feature Axial Fan Radial Fan
Airflow High volume, low pressure Lower volume, high pressure
Noise Level Generally quieter Can be noisier
Size Usually larger More compact
Typical Use Hotend cooling Part cooling
You can see these twin fan types combined in many 3D printers. For instance, a layer fan might be an axial fan, while part cooling fan for the engine (or hotend in this case) is radial. Even more advanced configurations can make use of multiple fans working at the same time to provide balanced coolant distribution.
Fans serve different purposes, thus each comes with its advantages based on the user’s cooling needs. For example, when selecting a fan for your 3D printer, the speed of the fan can make a significant difference in cooling performance.
To assist you with your precise cooling needs, ACDCFAN provides a multitude of fans including AC axial fans, AC radial fans, DC axial fans and DC radial fans to ensure quality and reliability. From 2,000 revolutions per minute to 20,000 revolutions per minute, ACDCFAN fans can effectively operate range and maintain impressive cooling to ensure your 3D printer performs at optimal levels. Whether high-volume airflow or precise, high-pressure cooling is needed, high-speed fans ranging from two thousand to twenty thousand revolutions per minute are perfect for the job.

Advantages and Disadvantages of Each Fan Type in 3D Printing

When it comes to choosing between axial and radial fans for your 3D printer cooling system, it’s not just about picking the “best” option. Each type has its own strengths and weaknesses, making them suitable for different applications. Let’s break down the pros and cons of each to help you make an informed decision for your 3D printer fan setup.
3d printer part cooling fan

Comparison of Axial vs. Radial Fans for 3D Printing

Axial Fans

Pros:
  1. High airflow volume: Axial fans can move a large amount of air, making them excellent for general cooling.
  2. Quieter operation: Generally, axial fans produce less noise than their radial counterparts.
  3. Energy efficiency: They typically consume less power for the amount of air they move.
  4. Cost-effective: Axial fans are usually cheaper and more readily available.
Cons:
  1. Low air pressure: The airflow from axial fans can be easily disrupted by obstacles.
  2. Less focused cooling: The wide airflow pattern can make it challenging to cool specific areas precisely.
  3. Less effective for part cooling: The lower pressure makes them less ideal for cooling freshly extruded filament.
Real-world application: Axial fans excel as 3D printer hotend fans. Their ability to move large volumes of air efficiently makes them perfect for preventing heat creep in the hotend assembly.

Radial Fans (Blower Fans)

Pros:
  1. High air pressure: Radial fans can direct a strong, focused stream of air exactly where it’s needed.
  2. Compact size: Their design allows them to fit into tighter spaces on a printer.
  3. Excellent for part cooling: The concentrated airflow is ideal for cooling specific areas of a print.
  4. Versatility: Many radial fans allow custom duct designs to optimize airflow.
Cons:
  1. Lower air volume: While the airflow is more focused, the overall volume is typically less than axial fans.
  2. Higher power consumption: They often require more energy to operate effectively.
Real-world application: As a 3D printer part cooling fan, a radial fan shines. Its focused airflow can cool newly extruded filament quickly and precisely, allowing for better bridging and overhang performance.
Remember, many modern 3D printers use a combination of both fan types to leverage the advantages of each. For example, an axial fan for the hotend and a radial fan for part cooling is a common and effective setup. Some advanced setups even use multiple radial fans for even more precise cooling control. Thus, don’t be afraid to experiment with different fan types and configurations to find the perfect setup for your 3D printing needs.

How to Choose the Right Cooling Fan for Your 3D Printer

While selecting a appropriate cooling fan for a 3D printer can be difficult, it becomes easier if an appropriate plan is put in place. Try delivering prints whose quality is exceptional, no matter if you are upgrading your printer or constructing a new one from scratch. Let’s look at some of the considerations you need to take to choose an appropriate printer fan.

Factors to Consider When Choosing a Cooling Fan

  1. Printing Materials: You may use a diversity of materials while printing which require a distinct cooling mechanism. For aggressive cooling, you may use a powerful radial fan for printing with PLA. However, a moderate setup is favorable for others, such as ABS, which requires less cooling.
  2. Print Quality Goals: When it comes to prints, the focus changes a lot from agle finer details to speed and vice versa. It is possible to acquire the needed intricate glace with a high pressure radial fan which focuses on high airflow, while for general purpose prints good axial fan should serve as adequate.
  3. Noise Considerations: Using a low noise axial fan can serve as an advantage if you are printing in an enclosed space with a shared environment. Make sure the performance of the fan serves critical cooling needs if it is meant for specific prints.
  4. Size and Compatibility: Verify the size of the fan before installing it to your printer. The suppliers of 3D printer fans usually have 40mm or 50mm fans, but you can find different sizes. Additionally, ensure the voltage of your fan is compatible with your printer, as it can either be 12V or 24V.
  5. Airflow vs Pressure: For cooling parts, fans with high static pressure (usually radial fans) should be preferred. For cooling the hotend, however, the airflow volume is usually more important than the type of fan (axial fans) used.
  6. Upgradability: Fans that have custom duct designs should also be considered. This would enable you to optimize your cooling setup more easily in the future.
And finally, think about what’s in store for you down the road. A 3D printer fan upgrade, for instance, is an affordable way to make a recognizable difference in print quality. Some printers even allow for the use of an additional fan or a 3D printer exhaust fan to be used when enclosed.
3d printer parts cooling fan

Installation Tips for 3D Printer Cooling Fans

Whether you are changing an existing cooling fan or installing a new one, there are some things you must do for your 3D printer that will ensure the unit properly functions after the installation. If these steps are taken, the process of replacing the fan or adding a 3D printer auxiliary fan will go smoothly.
  • To begin, remember to switch off the printer and allow it to cool down completely. This must be habitually done before installation or upgrade of a 3D printer cooling fan. Other tools needed are wire strippers and screw drivers.
  • For old fans, unscrew any visible restraints on the fan. Separate the fan wires and observe the orientation of the fan as you dismount it.
  • Examine the screw holes on the new fan and make sure the airflow direction is correct else it will be futile.
  • Alteration in fan type can result in change in appliance. Thus, new brackets or accessories may be required for compatibility.
  • Customize the wiring by matching the positive and negative connections to their respective colors, red to red and black to black. Remember to cut or solder any loose ends. If using a part cooling fan, attach the duct in a way that ensures optimal airflow without restricting the motion range of the printer.
  • Switch on the printer and see if the afore mentioned fan is in good condition. If there are any strange vibrations or sounds coming from the fan, turn off the printer immediately. Make adjustments to the settings of the printer according to the manufacturers specifications and return as necessary depending on the print results.
Additional Tips:
  • Adequate cooling can be achieved with a powerful fan but cooling the hotend too much is risky. Therefore, appropriate Strength of 3D printer blower fan must be selected.
  • In case you put a 3D printer exhaust fan in an enclosure, be sure to address the temperature compartment as well so that the optimal conditions for features printed in ABS are preserved.
  • For the fan mounted on the 3D printer hotend, it is advisable that the fan runs at all times in order to avoid heat creep.

Conclusion

From what we have seen in this guide so far, 3D printer cooling fans make a difference in achieving the best quality prints. Identifying the different kinds of cooling fans and knowing how to choose the best for your situation and how to install it are all good steps toward improving your 3D printing experience.
The development of new 3D printing technologies is bound to increase the number of cooling solutions available. This is where multi-fan setups and other smart cooling systems which change according to the print parameters are introduced, and boom, the future of 3D printer cooling is just amazing.

ACDCFAN: High-Quality Cooling Fans Designed for 3D Printers

ACDCFAN is an experienced manufacturer of robust cooling fans for 3D printers that have high performance capabilities. Our fans have an aluminum alloy frame casing which has been reinforced with 3-5% copper for extra strength and longevity. The fans adhere to the ROHS 2.0 guidelines, assuring both high quality and environmentally friendly design.
Cooling fans featuring NMB bearings guarantee efficient performance at high temperatures of 40 degrees celsius and beyond. These fans can be relied upon for a whopping 70,000 sequential hours of cooling, which is ideal for 3D printers as it can help reduce overheating, enhance printing quality, and more add years to its life span.
Our cooling fans come in sizes between 25mm to 254mm, satisfying a variety of needs. ACDCFAN has the best supply chain management for clients that require timely delivery availability. With a minimum wait time of only 7 days, we are a great partner for B2B clients needing superior cooling fans for 3D printers. Varying from importers to distributors, we can guarantee that you will be satisfied with the performance and delivery of our fans.

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