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Since swapping from Marlin to Klipper and printing at a wall speed north of 100 MM/S I have begun to be bound by cooling. My “minimum layer time” I couldn’t get under 10 seconds without seeing issues on small models. This began quite the journey of printing up various cooling options and I think finally after a half dozen tests, I have landed on what I think is the best fan solution for my printer.

In the post below I am going to loosely “review” the models I printed and tested as well as give my feedback. Some models are better than others, and all creators deserve praise for not only designing their own cooling solutions but sharing them. I am immensely grateful for their contributions to the open source community. My goal here is to have people looking for a cooling solution to not have to waste 24+ hours printing up cooling solutions that I have found do not work for my particualar printer setup.

TL;DR; The best system I have found to date

Ultimate 5015 Part Cooling Dual Fan Duct for Ender 3 S1 (Pro) + Sprite Extruder

PROS: Not a huge cost, no need to heat sink couplers, no real assembly, works the best

CONS: Need to have a good cooler already to print without excess supports, Fan position pushes against CR Touch eventually will cause fatigue in the PETG.

The Rest: In no particular ranking

Ender 3 S1 5015 Fan Duct

PROS: Easy to print, similar style to stock fan

CONS: Cools worse than stock fan. The angle from the fan to the aperture is so extreme that much of the velocity is lost to entropy creating a worse cooling system than stock

Ender 3 S1 Fan Duct Simple Improvement

Ender 3 S1 Fan Duct Simple Improvement

PROS: Prints in under 20 minutes, designed for stock cooler, definitely shows an improvement over stock cooler. I printed in PETG but I bet PLA would be ok.

CONS: Still bound by the limitations of the stock cooler

Ender 3 S1 Twin Jet 5015 Fan Duct

Ender 3 S1 Twin Jet 5015 Fan Duct

PROS: None

CONS: The design of this had the screw holes not line up with the fan, the adjustability is limited, the extruder magnets mess with the fan and most importantly the design SEVERELY limits airflow. The design makes the air turn 90 degrees, then another 90, and then another 90 to get to the part.