Electric Fan

My Electric Fan design focuses on ease of assembly, customisation and practicality. With a sturdy base, protective grille, and easy-to-use controls, it offers both safety and convenience. Its portable nature means it can be used anywhere without relying on a mains power supply, making it ideal for both indoor and outdoor use. It's customisation enables you to use higher power motors, more batteries for more power, self customised body frame, modifications like variable resistor for speed control and more..

1xElectric dc motor

1xpropeller

1xbattery set

1xbattery connector

1x switch of any kid

3 x AA batteries

Electrical wires

CAD software: Fusion 360 or any

3D printing service

Filament: PLA basic

Slicing software: Bambu Slicing software

You have to think about the environment and spaces this fan will be in and thus consider the diameter of the fan cage, for example if you are only using it at your house you can make the cage with higher diameter to enhance the air output, however if you are someone who likes to travel it is better to make it smaller to fit nicely in bags. You also need to consider the length of your propeller when designing the fan cage. In my design the cages are planned to connect together using a joint where there is a stick on one side and a hole corresponding on the other side.

Before creating the battery holder, it’s important to take accurate measurements so everything fits together perfectly.

Measure the battery holder size:

1. Measure the height, width and the length of the battery holder.
2. Make sure there is enough tolerance to add the wires to the switch so it is easy to add the circuit.

Add ergonomic to the design:

1. On the back of the holder, design finger grip curves so it’s comfortable to hold.
2. Make sure these curves don’t interfere with the battery compartment or other components.

Measure dimensions of the switch

1. Measure your switch's length, width, and depth.
2. Create a hole in the holder that matches these measurements.
3. Position the slot close to the battery compartment so wiring stays short and tidy.

Choose the Switch Side

1. Decide which side to place the switch based on how you’ll hold the device(left or right handed) and which side is easiest to reach.

You also need a hole from the inside the battery holder to the outside for the wires to exit. For this I recommend a hole that can fit 2 wires with some tolerance. This makes sure that the wires can slide in and out easily making it easier to attach other parts.

So we start off by exporting stl file from Fusion 360, which is provided below. This stl file is sliced using a slicing software, I used a software called Bambu studio to slice my design. Make sure the design bodies are placed with a flat face and in a way that require less support and filling. You can use the auto arrange function in the software to automatically arrange it for you.

The electronic circuit is a simple fan-switch electrical circuit. Make sure that the wires have enough length to connect every component.

1. Connect the battery connector to the battery case.
2. Connect the positive wire to the switch.
3. Connect the negative wire to the motor.
4. Add another wire connecting the positive terminal of the motor to the switch.
5. The wires connected to the switch must be connected in the order shown above.
6. You are done with the circuit

You can solder the wires in place if need and if the necessary equipment are available such as soldering iron and soldering wire(lead free to avoid toxic gas).

I used a super glue to attach the motors and other parts together, but you can use any strong glue like glue gun if available.

1. Attach the battery holder to the battery case using glue.
2. Pull the two wires connecting the switch and the battery out of the holder to the motor.
3. Attached the back fan cage to the battery holder + the motor to the back using a super glue
4. Connect the wires to the motor, make sure that the propeller is pushing the air in the right direction if not reverse the wire connection order.
5. Then attach the propeller to the motor and add the front cage.
6. Add the battery cover and your done.

We have made a simple basic electric fan you can add a variable resistor to control the speed, add compartment for ice or cold water to further improve the fan. For aesthetics you can use acrylic paint or markers to design the fan body. You can also upgrade the battery to rechargeable batteries to improve the fan's performance overall.

Thank you for you time, enjoy the fan.