FDM Cooling Vent

2023

The project involved creating a ventilation duct to redirect cold air from an air conditioning unit positioned inside a vent cover. The client's AC system was ineffective because cold air accumulated within the cabinet rather than distributing throughout the room.

Project Requirements

• Custom measurements needed for each unique AC vent distance from the grate
• Tight fit required to push air through efficiently
• Must be adjustable to grate height
• Installation without fasteners or permanent damage
• Fit within a 16"x16"x14" printer build volume
• No post-processing or support removal desired
• Design without overhangs

Development Process

Day one involved taking measurements. On day two, the prototype was tested and required adjustments to hole alignment. I manually modified the fit and created a corrected version while minimizing material waste.

Design Features

The final design consisted of two parts: one slotting into the AC unit and another extending upward to the grate. Initial single-filament thickness caused rattling when air flowed through; changing to two-line thickness resolved the issue. The interface incorporated slight draft angles to accommodate measurement tolerances.

Installation & Results

Installation completed in 30 minutes. Total billable hours: 10. Follow-up one month later confirmed continued successful operation.