HVAC Directional Floor Vent/Register

This is one of those times where I smacked my head and was like “How long have you had 3D printers, and you are only now realizing you can fix the crappy vents?”  Some times I'm real special.  I know there are a few other options out there for printable floor vents/registers, but a lot of them seen to be the same generic thing or require 2 pieces to fit a vent.  Most of them also just use the generic short fins or some pattern that doesn't really create good flow paths out of the vent and just kind of blows it wherever.

• Goals
  • Replace pop up vents that take up space and don't stay up because my dad insists on stepping on them. 
  • Low profile so easy to get a vacuum over it. 
  • Single piece print.
  • Better vent design that doesn't just create a turbulent mess. 
• Results
  • All vents run 0.25" undersized for a loose fit since no vent is perfect.  If you want a snugger fit, I suggest adding a little foam tape in a few spots to reduce movement (some like 1/2in wide by 1/8in thick should work).  The cover is 1.25" oversized compared to the vent size.
  • Profiles available for the following vent sizes:
    • 2x10"
    • 2x14"
    • 2.5x10"
    • 2.5x12"
    • 3"x10"
    • 4"x10"
    • 4"x12"
    • 6"x10"
    • 6"x12"
  • Other Models
    • Closed Vents
  • Planned/In development Sizes
    • No other sizes currently planned, but open to requests for different sizes. 
  • Used longer channels to create actual flow paths out to let the flow “attempt” to develop before it leaves. (don't currently have cfd access right now so mostly theoretical till I can prove it, but it's working really well). 
  • Low profile design 2.5mm thick top
  • Multiple angle options available (45°, 30°, 15°, and 1°), all marked with labels and direction flow points.
  • Single piece print with custom solid supports that you can brake off by hand.  (I'm really happy with how this came out, I know there is some extra waste, but it works really well)
• Mounting Screws
  • The top flange is printed with 100% infill so you can drill and/or countersink anywhere you need to for mounting screws, so I won't be uploading profiles for predrilled parts.  Given the possible number of screw sizes, types, and mounting patterns this just seems to make the most sense. 
  • For this test I just used a #8 wood countersink drill (tool example) and feel like this is cleaner then printing it.  Alternatively if you wanted to use a pan head screw or something with a flat back you can just drill a simple hole. 

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• Cleanup Notes
  • There is a little cleanup on the bottom edge, I just run a debur tool over it lightly and it cleans up just fine.
  • I don't do anything where the triangles and the back support come off.  I just use them as is. 
• Misc Notes
  • I designed this using PETG just to have something that will hold up better over time.  You can probably print this in PLA just fine, just not sure how it will handle the hot air in the winter time, so PETG seems like the better option. 
• Larger Format Printers
  • If you can fit this on a larger printer face down go for it.  It's already designed to be printed in that orientation.  Just remove the 3 extra support bodies and you should be good to go. 
• Load Testing
  • For those wondering if it can take weight the answer is yes.  I blurred out my bare feet so no one here has to look them, but I weigh 240lbs and this is only supported on 2 of the 4 sides and it deflected a little bit.   This is also a really large vent.  My normal 4x10s don't deflect when installed and me standing on them. 

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