Humidifier Fan Blade

A couple years ago, one of the fan blades from my humidifier broke, but I couldn't find a suitable replacement. I watched a couple videos of creating fan blades with Fusion 360 and was able to create my initial design. It had more surface area than the original blades. On low, the blade seemed to move as much air as to the other blade on high. But was also as loud as the original blade on high. 

The replacement worked ok for a couple years, but my wife finally got fed up with having to turn off the humidifier when trying to watch TV.  

Since I still had my original design I made in Fusion 360, I was able to modify the blade profile to more match the surface area of the original.  I added a couple parameters to help tweak the design, but pretty much everything can be changed from the timeline.

Since I used my new Bambu X1C to print the fan blade with a smaller layer height, it is considerably smoother than the original. This also contributes to it being quieter. And I didn't have to do any post processing.

We have used the new blade for a couple months.  It is so quiet that we can leave it on medium speed all the time.