The Mini-Blower Fan is a high-efficiency, portable air-moving system designed for maximum airflow in a compact footprint. The project balances practical electrical wiring, tight mechanical tolerances, and rigorous functional optimization.
Technical Specifications
- Core Components: 5015 DC 24V Blower Fan, TP4056 Charger, DC Step up Converter.
- Power Supply: High-capacity 3Ah Li-Po Battery, ~5hr runtime.
- Design Priority: Prioriteses space, making the whole thing look very bare-bones
Engineering & Fabrication Process
1. CAD Modeling & Mechanical Design
The entire enclosure and mounting mechanism were designed from scratch using Onshape. Special consideration was given to creating precise press-fit tolerance slots for the heavy 3Ah battery cell, eliminating the need for excessive gaps or space usage. CAD Link: https://cad.onshape.com/documents/eb171909497f7c5a1e10d912/w/ab35d0140865971304331106/e/bc15d2978612702b96321dfa?renderMode=0&uiState=6a4192409a392f71b3d4849b
2. 3D Printing & Tolerances
Fabricated via FDM printing using Orcaslicer to fine-tune the slicing profiles. Because this design relies heavily on airtight directional pathways and mechanical snap-fits for the housing halves, dimensional accuracy was critical. Instead of using a normal 0.4mm line thickness (for my 0.4mm nozzle), I turned it up to 0.6mm, meaning it squeezes out the plastic, making it airtight and forming a strong bond with the adjacent wall.
3. Electronics & Integration
The battery is wired to the TP4056 Charger, which offers easy and quick charging at 1A, then goes to the step-up converter, which can be configured to any voltage (fan speed control), which then goes to the fan. There is a switch between the TP4056 and the converter to turn the fan on/off.