Chilly - the Food Chilling Creature (Take 2)

This instructable can (potentially) improve your lunch time with little kids.
It does this by making the job of cooling the food accessible to the child, and fun.

It started several years ago, over one lunch time when my kid kept asking his daddy and mommy to blow on his food. Needles to say the adult conversation didn't happen that time.

This is how the original one was born.

Years passed and I only had that one. Then I improved it, over and over again, like here or here, or even here.
This version had more success and soon I made one for every friend of my son.

(Actually this is more like Take 8, and not 2, but let's call it an official v.2)

My son is all grown up and doesn't use it anymore, but my <2yo daughter does, and she loves it

Our table time improved and I hope yours will as well

Supplies

Here's what you're going to need,
If you're doing DIY for a while, you already have this stuff laying around, if not here are some links for you:

1. Small fan, 12v, these are commonly used for 3D printer heads (buy the 12v version):

http://ebay.us/HkQf4a

http://ebay.us/56coVv

2. Small momentary switch (different colors available)

http://ebay.us/UUirrl

http://ebay.us/t9mw2P

3. 2A voltage booster

http://ebay.us/X20XdW

http://ebay.us/CKgE2W

4. 1s charging board

http://ebay.us/FPNQvT

http://ebay.us/IQuUtD

5. 18650 lithium cell (Samsung, LG, Sony preferred)

6. Small Philips head bolts

http://ebay.us/hQY9ce

Also some basic tools required:

1. Access to 3D printer
2. Soldering iron
3. Hot glue gun
4. CA (super) glue
5. Some hand tools: screwdriver, stripper, etc.

Step 1: Print the Parts, Remove Supports and Sand the Interface

Chilly has 5 parts to print, all which can be found here:

https://www.thingiverse.com/thing:4728622

The head consists of two parts - front and rear.
The base consists of two parts - top (includes the neck) and bottom.
There's also one small inside bracket for the head, it holds the fan in place .

One remark here, I intentionally lifted the parts by 2mm from the bed - to build supports. I've found this helps with the quality of the joints.

Print and remove the supports.

Lastly sand the interfaces between parts that'll be connected later on.

Step 2: Assemble the Head

It's time to glue the back panel of the head to the neck.

Super glue (CA) is your friend here, the interface has enough area to bond. Make sure you align the head facing forward.

Next, connect the bracket to the fan. This is done with two screws and two tiny washers, see pictures.

*Pro tip: the bracket sits inside, so it can be any non-matching color with the rest of Chilly.

Now attach the bracket to the front head panel, two screws again, no washers needed.

Once the fan cable is inside the neck, assemble the two head halves with 5 screws.

The upper part is done!

Step 3: Top Part of the Base

Your newly assembled head includes also the top base part.

Two things need to be added here: the push button from the back and the voltage booster inside.

Solder the +/-out leads of the booster to the fan wires, then hot glue it inside.
*Note, the potentiometer screw needs to be accessible later on, see orientation in pictures.

Solder one side of the push button to the IN of the booster (choose positive or negative) and add one small wire to the other lead.

See that nothing is moving, and you're actually done with this part too.

Step 4: Bottom Base Assembly

Here we hot glue the 18650 cell inside and add the charging board to it.

Connect between the two.

Remark 1: The huge 18650 cell is not actually needed current wise, but it is needed to counter balance the head. So don't put something smaller

Remark 2: there are two types of this tiny 1s charging boards - with and without discharge protection - see here and here (both will charge though). Both can be used, and because the cell is huge compared to the fan current consumption, it doesn't even matter as there will never be an empty cell.