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New Year, New Printer and an Old Project

1/2/2026

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I treated myself to an H2C for Christmas, and just got around to setting it up yesterday.  The sucker weighs quite a bit, so I had to remember to "lift with your legs", but really it should be a 2 person lift to be safe.  Setup took a while to run though the calibrations, but so far it has been running pretty well.  I've not run any multicolor prints yet, but having a stash of ready to go nozzles in different sizes is really cool (even for single color).  But one thing I noted is that, despite having a pretty good sized filter, I can still smell the melted plastic when it's running certain materials (like wood PLA).  Based on the pics I've seen, it looks like the fliter either moves up and down, or there may be a door that blocks the bypass air.  I suspect the issue is that air can bypass the filter, due to the design of the exhaust system which has to do double duty as a filtered exhaust and recirculating filter (when running the heater).  I'd like to find a video which shows how the system works in detail (if I do, I will post a link).  It's a shame though, since it has a really big HEPA filter, with carbon, and the printer is much better sealed than the X1C (unfortunately it seems it's not as well sealed in the exhaust path through the filter).

The H2C is just a tad big for my current enclosure, (though I may still cram it in there), so I thought about bringing back an old (stalled) project which I never felt was tested enough to release.  It's an inline booster fan, designed to draw out fumes from the X1C (or any enclosed printer with the right adapter).  It should work with the H2C, and help pull the fumes out the back of the printer, where the exhaust is vented.  It may also help remove any air that slips by during the recirculation filtering too.

I was gonna work up an exhuast adapter, but found a really cool exhaust duct by Clough42 on MakerWorld, which is designed for the H2 series.  He kindly provided the STEP, so I reworked it just a bit to fit my existing hose couplers, and increased the standoff distance by 10mm to clear the poop chute (since it will bend to the left side of the printer).  I'm printing the adapter currently, and will need to order some screws to mount it.  The plan is to run a short hose from the adapter, over to an inline booster fan, and then duct it from there, out an unused doggie door.  Once I get the fume situation settled, at least for a while, I can get down to really using the H2C.  I also plan to (finally) release the remixed duct, along with my booster fan design, the hose couplers, and doggie door adapter, once I've got everyting running and tested (if it works well enough).  I've got a spares case update planned for it, and some other projects, where it should really shine with it's multimaterial capability.
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11/17/2026:  The new fan duct works well, but the old booster fan did not unfortunately.  The original booster fan I am using has one 6038 server fan, and it is not enough to move the enough exhaust air from the printer out through 10 feet of 2.5" hose.  It is almost enough though, since there is enough pressure that I can feel it blowing pretty well at the end of the hose, and there is enough pressure to actuate the louvers on my doggie door pass through duct.  But after a couple hours, the printer chamber temp triggers a warning.  I think it just needs a little bit more static pressure.

Fortunately I have all the parts to upgrade the booster to a 2x stacked 6038 fan config.  Unfortunately it's been a bit of a pain to get things working, since my Delta fans seem to have a different wiring setup by default, where the tach sense and pwm lines were swapped around.  Once that was sorted out, things worked though.  But the problem did give me a chance to try out my handy new-ish ZOYI ZT-703S multimeter with an oscilloscope function.  I wanted to confirm the PWM signal line and also check the sense return line from the fans.  It's auto range worked pretty well to home in on the signal, and then I added the frequency and duty cycle functions to the screen, so I could verify the signal from the controller.  It was a lot simpler than I thought it would be, since the UI is not bad.  I can see this being really useful for checking PWM signals or other stuff, short of checking logic signals.  I've actually avoided using this meter, since I tend to just grab my old basic meter 90% of the time (which works for 90% of the stuff I work on). 

With the PWM control working, I was able to test out a few different spacers for the stacked fans, and found that a 15mm spacer seems to work best (a 10mm and 12.5mm were also tried).  I'm currently running off the last few parts and spacers I need to test the stacked fan config with a live print.  Hopefully the double fan booster will be enough to keep the H2C chamber temps low enough during PLA and PETG prints.  If it all works out, and I have some confidence in the design, I may post it on MakerWorld.  However for the money, it would make more sense to buy a pre-built inline booster fan, since I expect the total cost to be around $45, with parts from AliExpress.  The fans make up half the cost though, so if they were obtained cheaply, it would bring down the cost quite a bit.
11/21/2026:  The stacked booster fan seems to be working well, since I can get through a whole print without the chamber temps changing much, and I don't need to run them at full speed even.  I'm thinking that I may take this project in a new direction though, since I would like to automate the fan and get some better speed and other data from it (to tune it better).  So I did some brainstorming with my "AI buddy", and now have a plan to use the Bambu integration for Home Assistant, which will allow the fan to come on when the chamber fan is enabled on the printer.  I'm also planning to add a few extras. 

The existing design did not have room for any extra components (to support the HA integration), and I think it needed a refresh anyway, so I redesigned it from scratch, with the aim of making it easier to build and maintain.  The new design is now mostly completed, but not tested (or printed).  I'm waiting on a few parts to finish up some of the details of the design, which I expect will be here in a week.
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11/26/2025:  The booster fan design was almost done when I decided, maybe it would be better to run one fan than two in series.  So I went looking for one that could work, and found two top candidates.  One is a Delta Delta 6038 PFR0612XHE which pulls 3.0A and could replace the two 6038's in my current stacked config.  The only problem is that the reviews say it screams like a banshee (not that any fan I could use would be quiet, but it makes sense being such a small fan that it must be very loud).  The other candidate was an 8038 fan, which I really liked the specs on, since I can downtune it for this application, and have headroom if I decide to really crank it up.  That would the ARCTIC S8038-10K, which runs about $16.  There is a 7k version as well, but it was only a buck less, and I think both will be about the same if I downtune the 10k fan.

So I went back and reworked the design to fit either a single (or a stack) of 6038's or one 8038 fan.  My current plan is to use the 8038, since the stacked 6038's I am currently running are making noises which gives me the feeling they may wear out prematurely in the stacked config.  The updated design also corrected some issues that I only discovered during the rework, and added a few new features, which I hope will make the design a bit nicer to use.  The new design will also feature an ESP32-C3 and a 1" OLED with 4 buttons for making some adjustments.  I decided to drop the external control pod which my current setup uses, since this design will hopefully leverage some automation using Home Assistant (though it will have a manual override function as well).  I'm waiting on the 8038 fan and some other parts, but once they arrive, I should be able to replace my stacked fan setup and test it out - though I also need to print the latest design.
1/28/2026:  Quick update on this one.  It's had a few more updates since the last post, and a completely new mounting system.  The change will require a single M4 brass insert though.  I also found a couple issues with my first prototype prints (as usual), so several small changes were made to fix those.  I'm currently printing it all over again (really the third time due to some impossible to remove supports, which I've corrected).  Once the fixes are checked out, I can then actually build this thing (well I can when I get the sensors and OLED display from AliExpress).
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2/2/2026: The good news is that I received the parts from AliExpress and finalized the design for the electronics and component holders (which fit).  The not as good news is that I now have a small box full of prototypes for this design, with almost a whole spool down the drain.  But I "think" the design is finally "done".  The prototypes could probably be used, but I still have to print the final design to make sure it all works.  This one had a bunch of small tweaks here and there, which were intended to help with printability, or fix small errors.  I unfortunately used up the color I intended for this design, since each of the prototype prints were supposed to be the "final design" lol.  In any case it probably won't matter what color it ends up, since it's gonna be tucked away out of sight anyway.  I still need to print it again, so hopefully I will have some progress pics in the next update.
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