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Dual stage axial fan

by BamJr May 1, 2019
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Have you had any luck designing something quiet enough to work for the job? I'm thinking of doing something similar. I find that the filters in my portable airbrush "booth" don't last long and particulates are leaking through. I'm thinking of routing the exhaust through a printed cyclonic dust extractor. Perhaps like this but with a bit more oomph (though not something with enough oomph to blow shrapnel): https://www.thingiverse.com/thing:3574173

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I did some preliminary calculations for a quieter design, but then a completely different project caught my interest. I was converging towards a single stage radial compressor, about 5" in diameter and spinning as low as 4000 rpm. Problem with that design was either I needed to run the motor much slower and draw more amps, which would've required a new PSU, or I needed a high speed gearbox. I was also cosidering a water based air filter, which would've helped muffling the sound and might have had a lower pressure drop. Routing such a high flow rate would've been a challenge though. The cyclonic separator is a pretty neath idea too!

What motor are you using ?

Brushed Tamiya RS540 Sport Tuned

Oh, fantastic, it uses a big RC Car motor and a normal RC speed controller , Something like the Reedy motors.

Yes, that's the basic idea. The motor was gifted to me by a friend who's a RC car enthusiast. Also, you could swap the RC speed controller with a simple PWM module like I did and it works just fine.

This is awesome. How do you balance the shaft?

Thank you! I used the parallel rod method similar to what can be seen in this great video: https://www.youtube.com/watch?v=3pG90WreWyo
I assembled the shaft complete with blades, bearings and locking nuts. Instead of adding screws like in the link above I simply sanded the blade tips. It's important to do this after the blades have already been glued to the shaft. Luckily my printer is quite well tuned and the assembly was balanced well enough without any major tuning.