多级旋转式尘埃收集系统

After printing, clean the inside surface from wisps, stringing, loose layers on top of the arches or other imperfections where dust would collect inside the cyclone. I used grit 40 sandpaper.

1st stage:
Screw Top1 and Bottom1 part together.
Use the Mounting Plate as a template to cut and drill holes in the lid of a bucket.
Attach Bottom1 to a lid of a bucket by mounting plate and 4 wood screws 5x20 or 4,8x22 selftapping screws with countersunk head.

Subsequent stages:
If building a multi-stage cyclone, every next stage will be assembled of Conduit, Top1 and Bottom2 parts. Conduit is attached to the tops by the same wood screws 5x20 or 4,8x22 selftapping screws with countersunk head, 8 pcs per 1 additional separator stage. An Insert-Grid or Insert-Smooth can be installed into the Bottom2 part to keep fine dust particles under it.

I already printed one cyclone dust separator https://www.thingiverse.com/thing:776415 but it eventually cracked due to a failure in my print after a few months of usage. Until then it was working fine.

I was looking for a replacement even before the cyclone cracked. Something like the SN50T33F with the second stage of filtration can be bought from Aliexpress. But it would take weeks to get it and I knew it could be printed quicker.

I found https://www.thingiverse.com/thing:4774999 that ticked most of my requirements but did not like the idea of glueing the whole thing together. Also, another bucket for the second stage would have to be used. So I ended up modeling the thing the way I wanted it.

The basic requirement was to fit the parts on a 200x200 heatbed and not exceed 200mm in height for a printed piece. Holes for the hoses were supposed to be 50mm in diameter. No supports are needed if possible or at least not on the inside of the separator. I also did not want to use any glue to assemble the whole thing. It would be mostly used for wood drilling, milling and occasionally sanding. The chips are mostly big (1 bucket a day) with a handful of fine dust that would end up in the vacuum cleaner. Hence the second stage would be a welcomed addition. But The most problematic for the separator are round drilling leftovers of 25mm diameter approximately 1mm thick that would eventually get sucked into the separator and fly there for quite some time. If enough of them get collected, they will eventually clog the first stage of the separator so it would have to be disassembled and cleaned manually. Removable top of the separator was a must. Although I knew already that the flat top of the separator worked just fine I liked the "snail" shaped vortex top more and it was also a challenging 3d modeling exercise :D.

It was modeled in Inventor, the design is mostly parametric and took roughly 10 hours including some final tweaks. For example, the version I made has a 3.2 mm thick wall, but the published one is only 2.4 mm to save some material and time. I also experimented with the length of exhaust inside the cyclone and the one published is what worked well for my use case. Last but not least the screws I used had 6mm thread but when shopping for them I realized 5mm can be obtained easier and are made in shorter lengths, so you would not have to cut them to 20 mm length. So far I have not used any sealant or glue yet the air leaks are not a problem (but there are some for sure).