Fab@Home:Fume Extractor

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1 Plastic Tool System Part 4 of 5: The Fume Extractor
2 Assembly

Plastic Tool System Part 4 of 5: The Fume Extractor

In this part we will assemble the fume extractor to take away the harmful molten ABS fumes

On Hand Assembly Tools and Parts for Plastic Tool

Soldering Iron for thermoplastic inserts and soldering
Needle Nose Pliers
Wire Strippers
5/64" Hex Driver
2.5mm Hex Driver
3mm Hex Driver
Exacto knife / scissors
Electrical Tape
Hot Glue Gun

Bill of Materials

Plastic Tool System BOM

Acrylic Parts

You can download the DXF files for the Plastic Tool System here and cut them out on a laser cutter:

Plain DXF Files
Cut compensated for Epilog Helix 35W laser engraver DXF Files

You can also use Ponoko to cut out all of the acrylic parts for the Plastic Tool System for you here

SolidWorks 2009 assemblies and part files of the Fab@Home Model 2.0 with the Plastic Tool System
Also contains laser cutting layouts in Solidworks 2009 drawing files.

Fab@Home Model 2 CAD with Plastic Tool System in Parasolid Format

Assembly

Duct Fan Assembly

Insert the the M4 threaded inserts into the 5 plates as shown (3 different kinds of plate). These inserts go into the larger holes (5.5mm)
[24x] M4 Brass threaded inserts
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Take the identical 5 hole threaded insert rings and gently and evenly push one over each end of the Duct Fan all the way
[1x] 3" Duct Fan
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Take the identical 5 hole spacer rings and gently and evenly push one over each end of the Duct Fan, but not all the way.
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Take the identical 10 hole spacer / threaded insert rings and gently and evenly push one over each end of the Duct Fan, making these plates flush with the ends of the duct fan. Secure all plates with M4 Screws
[10x] M4 screws 16mm length
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Take the two hose mount plates and Secure them plates with M4 Screws to the end of the duct with the fan as pictured. (inlet side)
[5x] M4 screws 16mm length
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Take the 5 identical small hose mount plates and Secure them to the large hose mount plate as pictured with M4 screws
[4x] M4 screws 35mm length
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Take the 1/4" Carbon filter sheet and the filter spacer ring, and cut out the inside diameter of the spacer ring on the carbon filter sheet with an extacto knife / scissors
[1x] 12"x12" 1/4" thick carbon filter sheet
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Take the cut carbon filter, the filter spacer ring, and the filter ring clamp and secure it to the outlet side of the duct as pictured with M4 screws
[5x] M4 screws 16mm length
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Plastic Tool Extractor Mount

Attach plates as pictured. Secure with #6-32 screws and nuts.
[8x] #6-32 screws 1/2" length
[8x] #6-32 square nuts
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Attach the top and bottom plates as pictured. Secure with #6-32 screws and nuts.
[8x] #6-32 screws 1/2" length
[8x] #6-32 square nuts
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Chassis Fan Mount

Insert the the M4 threaded inserts into the 2 chassis fan mount plates as shown. These inserts go into the larger holes (5.5mm)
[9x] M4 Brass threaded inserts
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Clamp plates to the far right side of the Fab@Home as pictured and Secure with M4 screws
[7x] M4 screws 16mm length

Final Assembly

Cut the 1" duct hose to a length of approximately 39" (990mm)
[1x] Roll of Duct Hose
Insert cut the cut hose into the Plastic tool extractor mount as pictured. Secure in place with the hot glue gun.
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Insert the other end of the cut hose into the fan duct approximately 35mm. Secure in place with the hot glue gun.
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Seal all gaps in the rings on the duct fan with the hot glue gun.
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Cut off the tip of the power supply and strip both leads. <<NOTE: The power supply pictured is an old power supply. Use the power supply specified in the the BOM>>
[1x] 12v 5amp power supply
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Solder the positive lead to the yellow wire on the duct fan and the negative lead to the black wire. Wrap all leads in electrical tape
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Attach the duct fan to the Chassis fan mount with M4 screws
[2x] M4 Screws 16mm length
Attach the the plastic tool extractor mount to the plastic tool by slipping it over the end of the SNAP motor and tightening the screws.