SUNLU S2 Aero Mod

NOTE: The mod is only compatible with the version of SUNLU S2 equipped with a fan.

THE AERO MOD

The Mod is intended to:

• Reduce noise.
• Improve airflow.
• Increase the dryer stability.
• Enhance drying performance using desiccant in the right place.
• Not increase the footprint.
• Be appealing from an aesthetic point of view.
• Be reversible and minimally invasive.
• Be printed in PLA and TPU on an 18x18 cm print bed (compatible with Bambu Lab A1 mini) without AMS.
• Facilitate the filament movement within the PTFE tube during printing.

The mod includes the following components:

• Rigid shell (PLA). The 3D model has a vertical notch so that the seam line is “nice” and straight.
• Inner body (95A TPU)
• Upper support for the fan (TPU 95A)
• Bottom lid (TPU 95A)
• Hole cap (TPU 95A)
• PTFE Tube adapter (TPU 95A)

MATERIAL

Required materials:

• Regular PLA (I used SUNLU PLA+ Black)
• TPU 95A (I used Kexcelled K7 TPU 95A Black)
• Noctua NF-A4x10 24V PWM
• Soldering iron
• A short piece of PTFE tube (optional)
• A PTFE Tube Coupler (optional) (I used https://store.bambulab.com/collections/spare-parts-ptfe-tubing-x1-series/products/ptfe-tube-coupler)

No other material is needed, as the original mounting screws are reused and the cables are already included in the fan kit.

WHY TPU?

Although TPU is not the easiest material to print with, it was selected for the following reasons:

• It allows parts to be sealed together naturally, preventing air leaks and having a simpler design.
• It is resistant to the temperature generated by the dryer.
• It absorbs vibrations and reduces the device noise.
• It allows a good level of grip between the dryer and the support surface.
• Can be printed by almost all modern printers.

INSTRUCTIONS

• Print all parts paying particular attention to:
  • dry the TPU filament properly
  • print the TPU with low flow/speed
  • use the type of plate suggested for each model in the Bambu Studio file if possible
  • use glue to avoid excessive adhesion of TPU on the smooth plate

BASE

• Remove the base of the dryer. The screws will be used later.
• Cut the fan wires, ensuring that you leave enough length to easily connect the new fan. This is the only step that is not completely reversible, although you can always re-solder the wires to restore the original functionality. I do not take any responsibility for any damage caused to the device.
• Take the extension cable included in the fan package, cut the connector on the power supply side, remove the outer sleeve and all the wires from the remaining connector except the yellow and the black one. Now solder the wires to those that were previously connected to the old fan (black to black and yellow to red). Make sure to insulate the connections properly.
• Place the outer shell over the inner body.
• Push the fan into the slot so that the wires are pointing downwards in the cable cavity and air is blown upwards (as shown in the photos)
• Position the fan top support, taking care to insert the extension cable in the side slot.
• Attach the inner body to the dryer using the original mounting screws. Ensure that the fan is oriented correctly and that the shell seam line is positioned at the rear (hinge side).
• Plug the fan to the extension cable. At this stage or later you can decide to insert the silent cable in between (not suggested). This reduces the noise slightly, but affects the airflow as it reduces the speed of the fan.
• Now you can insert a silica bag inside the air channel. The shape of the cavity is designed so that there is always a minimal airflow. In any case, place the silica correctly so as not to occlude the channel too much.
• Press the entire dryer over the bottom lid to close the base.

TUBE ADAPTER

• Insert the tube adapter into the rear hole (recommended). The design is asymmetrical so that the filament can move in the PTFE tube with a better angle. Rotate the adapter to achieve the optimal tube orientation. If you have a small piece of PTFE tube and a connector, you can attach them to the adapter. This way you can easily and quickly connect/disconnect the dryer to the PTFE tube of the printer.

HOLE CAP

• Insert the cap into the remaining hole only when the dryer is turned off to prevent moist air entering from outside.

MAINTENANCE

Make sure to replace the silica regularly. To access the inner cavity, insert a plastic card (credit card size) between the base and the lid as shown in the photos.

Enjoy your super dryer and happy printing!