Breathing solder fumes can cause serious health problems, a fume extractor is a cheap and easy way to minimize the inhalation of such fumes.

In this instructable I will show you how I designed and built this minimalist mostly 3D printed fume extractor; My goal was to make something functional, aesthetically appealing, inexpensive, compact and simple.

An important feature of this project is the removable filter cartridge that makes changing the activated carbon filter effortless and allows you to use the filters of the Hakko 491, 493, FA-400 fume extractors which are easy to find.

Let's get started!

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Note: Appropriate license attribution for this project.

"Minimalist 3D Printed Fume Extractor" by rdmmkr used under CC BY-NC-SA 4.0 / [List your modifications here separated by comma]

Step 1: IDEATION & DESIGN

After sketching and testing some ideas I came up with this design, then I used Fusion 360 to make the 3D model.

If you are new to 3D modeling and Fusion 360, I suggest you take a look at these classes: 3D DESIGN CLASS, 2D CAD AND CAM CLASS, DESIGN SKETCHING CLASS.

Step 2: TOOLS AND BOM

First of all I strongly encourage you to reuse those every day objects that you have lying around the house, find those obsolete gadgets take them apart and put some of their parts to good use.

If you can not re-purpose parts or you want and exact replica of this project, below I'm providing you links where you can find the bill of materials needed for this project.

TOOLS

3D Printer
Multimeter
Files & Sand Paper
Allen wrench
Digital LCD TS100 Mini Soldering Iron [Amazon]
Solder wire
Wire stripper
Phillips screwdriver
Wire cutters
Hot glue gun
M3 Hand Tap Drill [Amazon] [Aliexpress]

BILL OF MATERIALS

(Last updated: 2021-09-01)

(5pcs) 3D printed parts (I used PLA filament [Amazon])
(1) High air flow case fan 80mm x 80mm x 38mm [eBay] [Amazon] [Aliexpress]
(1) 80mm Black Fan Grill [Amazon]
(1) Rocker switch 2 ON-OFF 10x15mm [Amazon][eBay] [Aliexpress]
(1) Green 3mm LED [Amazon] [Aliexpress]
(1) 680 Ohm resistor [Amazon] [Aliexpress]
(1) 12V 3A Female DC jack connector 5.5 x 2.5 mm [Amazon] [Aliexpress]
(1) 12v DC power adapter [Amazon] [Banggood] (Make sure your DC Power adapter provides the amps your fan needs.)
(1) Activated carbon filter 130mm x 130mm x 10mm [Amazon] [Aliexpress]
(2) M3 x 10mm Button Head Socket Screws [Banggood] [Amazon] [Aliexpress]
(2) M3 x 3mm and OD=4.2mm inserts [Amazon] [Aliexpress]
(20cm) 22 AWG wire red and black preferably.[Amazon]
(4) M5 x 10mm pc case mount screws [Amazon] [Aliexpress]
Shrink tubing [Amazon] [Aliexpress] or Liquid Electrical Tape [Amazon]
(4) Rubber feet [Amazon] [Aliexpress]

Update: You can use this 12v DC Power adapter 5.5mm x 2.1mm Plug [Amazon] with this 12V 3A Female DC jack connector 5.5 x 2.1mm [Amazon] instead of the 5.5 x 2.5 mm power adapter and connector.

All components and materials are easily sourced, the links might expire but I will try my best to keep them updated.

Step 3: PRINT AND PREPARE 3D PARTS

You can download the STL files on Thingiverse

I have printed the enclosure with PLA filament on my Monoprice Select Mini v2 3D printer using Cura slicing software (see picture for the settings I used).

In order to minimize post processing I made a two part design for the enclosure and cartridge this way you won't need to print supports and post-processing is going to be minimum.

Drill and tap the threads with a M3 bit tap, then use your soldering iron tip to heat the inserts and press it into the PLA plastic when it gets hot enough.

Tip: Tap the insert again after attach it, it will make easier to insert the screws later.

Step 4: ASSEMBLY

Sand and file all the rough edges.
Insert the fan to one half of the enclosure, then attach the other side, parts should fit snugly together.
Make sure cut a notch in the fan so the wires can slide easily, also get rid of the signal wire (usually a yellow wire).
Cut the 130 mm x 130 mm carbon filter in half both ways, you will end up with 4 equal size pieces, we will use 2 pieces to improve filtration; add the carbon filters to the cartridge one in each side and snap it together.
Attach the fan grill to the back, my fan came with a grill and (4) M5*10mm pc case mount screws so I reused them.

Tip: If you don't have the fasteners you can use super glue for a permanent joint.

Step 5: WIRING AND SOLDERING

After snapping together the two sides of the enclosure, pull the wires to the front and solder all the connections as shown in the circuit schematic (make sure the polarity of the DC jack connector and DC power jack match).

Don't forget to use heat-shrink tubing around exposed wires and connections to insulate and protect the wires from abrasion.

Finally add some hot glue to the switch and LED to hold it in place and install the lid with the two M3 screws.

If you are new to electronics, I suggest you take a look at this class: ELECTRONICS CLASS

Step 6: THANK YOU

Thank you for looking, if you found this project helpful please vote for it in the contest and don't forget to share your build and comments!

Please consider following me on: Instagram

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Note: This post contains affiliate links, I earn a small percentage from qualifying purchases made through these links at no additional cost to you. Most of the links I post are to products I recommend and find to be a good fit for the project, always considering the best value for your money. I really appreciate your support, please don’t feel obligated to use them.