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A Corsi-Rosenthal style box that can be 3D printed

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3D printable Corsi-Rosenthal style box for PC fans

Some links to explain what a CR box is:

Here's a page featuring a lot of the original design: https://cleanaircrew.org/box-fan-filters/

Next is a showing that it works well with a 10" filter setup: https://www.texairfilters.com/a-mini-corsi-rosenthal-box-air-cleaner/

And then we get to the latest developmens where PC fans are showing to provide excellent air flow and remaining quiet: https://covid19crowd.com/cr-boxes/

Devices like this are also used in wood shops to capture small particles. I thought I'd build a small one for home because I have chickens in my office right now (yes, seriously) and they kick up a bit of dust with the food and straw and what not.

image *(A completed version with 80mm slim fans)

image

(A partially completed version. You can see the fan plate, corner plate, a 25mm wide plate, and a 120mm wide one on the bottom)

image

(A more completed box with 65mm corner plates, 121mm fan plate, and non-fan plate stretched to 120mm on the other three sides)

image (A completed box on the right with white duck tape used to cover all seams. This is built with the currently published 4mm thick plates. The one on the left is a test in progress using 2mm thick plates.)

cr80_inside cr80_front_open

(An 80mm PC fan version that requires no screws)

3D printing the frame

There are 3 types of parts you need to print. A plate for holding each fan, which are sized at 120mm wide for full sized fans or the slim80 versions for a 80mm fan version that requires no screws. You'll also want to print some corner pieces. A couple sizes are pre-generated for you. Last is the 'nofan' file which is a solid plate that is used to fill in between the corners and wherever you have a fan.

A quick and dirty way of doing it is to print the fan plate, print the corner plates of 25mm size, and a few 25mm nofan plates. You can then use tape to cover the holes left behind.

Or if you want it more solid, print the fan plates you need print the larger corner pieces, and use the nofan_plate_100mm and size it to whatever you need to. Being 100mm wide it's easy to figure out how to scale it. Need a 37mm section. That's 37% in the proper axis.

STEP files are also inluded so you can pull them into any CAD software and extrude it as you need.

Odds are the size of your bed means you'll need to print it in pieces. This would be a great one to run off on a belt printer.

The originals were geneated with CadQuery 2.0 (https://cadquery.readthedocs.io/en/latest/) with the code residing in grpc.py in this repository.

Fans and Power

For the 80mm builds I used thse fans: https://www.amazon.com/gp/product/B09B6SZ8XY and if you want 4 fans a power panel like this is handy: https://www.amazon.com/dp/B07M5P7VHG but you can run up to 3 fans without the panel using a supply like this: https://www.amazon.com/gp/product/B09V1BMSVP

I find 4 80mm fans make some noticable noise but it's about whisper level.

For the 120m builds if you're unsure here's the set I purchased: https://smile.amazon.com/gp/product/B08R8M17S2 which have the 4 pin and 3 pin connectors. I can daisy-chain the 4 pin connectors together and apply power to one and they all fire up.

For a power supply I grabbed this: https://smile.amazon.com/gp/product/B071FNN9W7 which can output 1 amp of power. That is enough to run 4 of the above fans at max speed.

I left holes in the fan mounting plate for 4mm machine screws but 6/32 or 3mm will likely work fine. It's not a fussy operation.

So, for about $25, a bit of filament, and the cost of your filters and you're in business with a decent quality and nearly silent air filter.

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