Autodesk Fusion 360 would be a great tool to use. It has a sculpt environment that is intended to handle organic forms. Powerful free-form shape tools.

https://www.youtube.com/watch?v=NypRE2aFhh4

insta wrote: I will trade you a PEI MIC6 bed for a 50mm fan duct STL that fits my setup and can be printed without much in the way of supports.

I'll gladly take that offer insta... if your need is not urgent. It may be several weeks as my schedule is going to be a bit congested.

Yes thats the esun carbon filled nylon Have you used this material much? How are adhesion and stringiness properties? What size nozzle? I have read that the fibers tend to like a 0.4 nozzle or larger. I have been looking at the Colorfabb XT-CF20 which is a carbon filled PETG. I have also looked at ...

Nice looking rig, and interesting analysis. I'll try the cone thing on my duct setup. Thanks zemlin. A cone should make an improvement to any ducted fan arrangement. It occurs to me that a cone might also be beneficial for non-ducted bed fans as well. Air passing over the surface of the cone will t...

very similar to mine IMG_5929.JPG Indeed it is Jim; very much inspired by your design. I was initially going to print and use yours but wanted to "tinker" with it a bit. One thing led to another and before I knew it I had spent far more time making modifications than I had planned. Is the photo of ...

To beat a dead horse... I decided to run a CFD check on the whole bed fan system as an assembly. Interesting results. Found turbulence downstream of the fan motor support plate (see graphic). This structure is the same diameter as the hub of the fan. Gluing a simple cone to the back of this surface ...

CFD of the fan guard looks promising as well. Very little pressure drop (<0.09" H2O) and good distribution. Knock off a few of the sharp, interior downstream edges and it should be in good shape.

Thanks Insta. For grins and giggles I ran a simple CFD analysis on the duct assuming a 0.1" H2O static pressure at the inlet. Distribution looks nice and it seems the tongue in the center nudges air to the perimeter on either side which is what I was hoping would occur. The simulation does not take ...

I have not worked with the black 910. While 910 is not a PET based material (its a nylon alloy) Jules' write-up on PETG does have helpful information related to troubleshooting principles. The blobs/balls are most likely caused by what Jules has pointed out. Nylon can be stringy and the little hairs...

Finished the attachment design and fan guard. Mounting bar (green) is held to the extruder mount (brown) by two machine screws. Duct (blue) attached by means of a dove-tail tab. Should be easy and quick to install/remove. Fan guard is a new design intended to reduce noise level and improve airflow. ...