Finished Bondhus fan racks
Lightweight density revision
The outside part, tested sockets and print orientation are unchanged. Narrow 100% infill zones replace the previous broad solid cores. Bulk is 5% gyroid with three continuous walls; all three use normal/grid supports in the recorded review slices.
- 13190 Inch: 520 g, down from 1021 g (49% less).
- 13189 Metric: 488 g, down from 973 g (50% less).
- 33034 Torx: 331 g, down from 665 g (50% less).
Solid zones: 1.6 mm bed-face foundation, 1.2 mm socket bands and load-path plates, 2.5 mm root widths, local 5.5 mm radius peg-root discs. Density-only parameters are separate from the outside construction. Strength changes with the material reduction; physical load qualification remains separate.
Three single-set racks: 13190 inch, 13189 metric and 33034 Torx. Compact swept handles, long straight sleeves, integrated print-plane gussets and restrained outside tapers. The chosen tip-end bed face is fixed. Tested socket fits remain unchanged.
Download all three: native FreeCAD, STEP, Orca projects and construction sources
Outside housing growth is limited to 30° from print Z; contraction is unrestricted. The original pegs and internal bore bridges are separate support cases. Four nonphysical modifiers make the bed-face foundation, peg roots/collector belts, sleeves/floors and sleeve-to-back load paths 100% infill. Bulk starts at 5% gyroid, three walls.
13190 Inch fan
Orca project: four 100% infill modifiers · Print-pose STEP · Editable FreeCAD
Nominal print envelope: 212.2 × 213.2 × 216.0 mm. Minimum bed-edge margin: 21.4 mm. Recorded P1S/ASA slice: 18h 39m 9s, 520 g.
Front, plan and chosen bed face
13189 Metric fan
Orca project: four 100% infill modifiers · Print-pose STEP · Editable FreeCAD
Nominal print envelope: 219.6 × 220.4 × 196.0 mm. Minimum bed-edge margin: 17.8 mm. Recorded P1S/ASA slice: 17h 8m 42s, 488 g.
Front, plan and chosen bed face
33034 Torx fan
Orca project: four 100% infill modifiers · Print-pose STEP · Editable FreeCAD
Nominal print envelope: 183.2 × 190.9 × 148.0 mm. Minimum bed-edge margin: 32.5 mm. Recorded P1S/ASA slice: 12h 0m 24s, 331 g.
Front, plan and chosen bed face
Connected reinforcement v3 fixes the gaps left when the old rib attachments were retained during thinning. Rib ends now overlap the socket bands and enter the rear wall skin; roots stay within the receiving plate. All 78 sampled sleeve contacts across 26 tools overlap in native CAD. The gray in the mask diagram includes solid perimeter walls as well as sparse infill.
Actual Orca paths before and after the attachment correction
Where the solid material goes
Actual XY sections; bed yaw is undone for readability only. Reinforcement directions are independent of the fixed print orientation. Masks may extend through air as selection handles; Orca intersects them with the physical holder. Never fuse them into an ordinary print part.
Edit and print preparation
Extract the bundle and run SETUP_DENSITY_FANS.FCMacro once in FreeCAD. Open the matching FCStd. 86 DraftedHolder is the current physical part; older bodies and clipped cores are hidden construction history. Toggle DensityHelpers to inspect the four zones. Install the supplied modules before recomputing.
Open 3MF files as projects. Confirm four Modifier parts, each at 100%, and one socket support blocker. Downloads are nominal/unscaled, with no private printer profile or G-code. The inch project requests normal/grid supports to keep its footprint on the bed; all three were reviewed with normal/grid supports. Select your actual calibrated filament profile, compensate once and review supports. The recorded slices used the owner's captured P1S 0.4 mm / 0.20 mm / calibrated ASA profiles; estimates depend on those settings.
All three STEP files reload as valid single solids with bounded volume/bounds and native surface checks. All four modifiers survive Orca slicing; repair counts are zero, extrusion centerlines stay on the bed, and the bounded socket-core screen finds no trapped support paths. Rear-peg mesh seams use the recorded bounded tessellation adapter; native CAD is the manufacturing reference.
Fit scope: +0.38 mm total across flats follows the winning 3C/5C coupons. Other sizes and long sleeves still need physical fit confirmation. The 2 mm key may rotate. Torx circular seats use catalogue tip envelopes; full-shank fit and handle rotation remain provisional. These files have no physical load or support-removal rating. The 30° check covers uncut outside housing facets, not every internal cut or peg underside.
Checks and exact download hashes · Construction source · Workshop design guide (HTML download)