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test die cast heatsinks
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Description

E3d is replacing there machined heatsink for the aero with a die cast version that should reduce cost.
We need to test the heatsink and see if it can be used as a drop in

Event Timeline

west created this task.Aug 20 2019, 1:42 PM
west added a comment.EditedAug 20 2019, 1:46 PM

I did some thermocouple testing on a regular heatsink and a die cast to see the differences by placing thermocouples in the fins both at the top and bottom. On average they are very similar

Next test will be with a thermocouple just above the melt zone in the heatbreak to see the internal differences

(edit- updated spreadsheet with new data from heatsink/heatbreak test)

It looks like the original machined heatsink is better but the die cast isnt much worse at normal printing temps.

Something else we will have to consider is mounting the 5v fan. We will either need to have the heatsink tapped for M3 screws or switch to using the self tapping screws that are provided in aero kits. @cmerot @logan do you see issues with using self tapping screws for this?

west reassigned this task from west to adam.Aug 20 2019, 2:58 PM
logan added a comment.Aug 26 2019, 9:06 AM

@west They currently tap those locations for us in the machined heat sinks right? Is there concerns with doing so for the die cast ones?
Ultimately, socket cap hex heads are sturdier and the self tapping screws are Phillips if I remember correctly. The aesthetic appearance will change due to the color of the fastener also. This would require stocking a different fastener as well.
Would this heat sink change apply to all Aero hotends?

That said, if it is easier (and thus cheaper) for the supplier, the function is comparable, and everyone is good with the aesthetic changes it comes down to the balance between the cost reduction from the supplier (if applicable) and the cost of stocking another fastener, updating all of the BOMs, and updating all of the OHAI kits.

west added a comment.Aug 26 2019, 9:11 AM

@logan, they dont tap the holes for the fan for us. We are essentially wedging the screw between the fins. With the new heatsink, the holes no longer align with gaps between the fins, there are untapped posts.
The plan is to roll this new heatsink in on all aero toolheads. @adam do you know the saving going to the new heatsink?

adam added a comment.Aug 29 2019, 11:42 AM

E3D can't drill and tap those holes right away and if they do set up for that the cost savings will be minimal from the milled heat sinks.
@west found some self-tapping screws that should blend better than the stainless steel: https://www.mcmaster.com/90935A135
We are still looking at a new screw with a phillips head instead of a hex.

logan added a comment.Aug 29 2019, 1:30 PM

I don't see any issue with using those, I think it will look better than the silver ones. Lets do it!

logan added a comment.Aug 29 2019, 1:32 PM

@west just for my own curiosity do you have any pics of the die cast heat sinks?

logan added a comment.Aug 29 2019, 1:41 PM

Glad I asked, those look sweet!
Them being black definitely reinforces wanting black screws.
Thanks

west added a comment.Sep 4 2019, 1:33 PM

I received 100 of the black oxide screws listed above and they work with the die cast heatsink

logan closed this task as Wontfix.Oct 10 2019, 1:17 PM

would've been nice