Printed remake of a broken cardboard handheld fan

Nov 10, 2026 Last reply: 2 hours ago 3 Replies
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The detail that caught me off guard is the front grille: a pink safety guard with two curved, ear-shaped loops, sitting in front of a three-blade pink impeller. A guard that protects curious fingers while looking playful at the same time seems like a really charming design choice.



The story behind it is just as good. The original fan belonged to the maker's daughter, was built out of cardboard, and had broken. After confirming the salvaged motor still worked, the maker designed a complete new body in Fusion 360 and printed the parts on a Prusa i3 MK3S+. The old switch and a 2x AA battery pack were reused too, which I think is a nice bit of thrift.



The details that stand out: the handle is off-white with a honeycomb cutout pattern and a slide switch marked ON and OFF. Brass threaded heat-set inserts were melted into the casing, and small screws fasten the frame and secure the motor hub assembly. Assembly called for a soldering iron, tweezers, screwdriver, wire strippers and pliers, with the motor and battery wiring soldered, trimmed and routed inside the housing.



Airflow was demonstrated against a thin foam strip, and the finished fan was shown running on a car dashboard and hanging on a workshop rail. The maker called the build a big success. One part remains original, though: the cardboard blade was kept out of safety concerns around a young child, and there was no time to model a printed blade and shaft coupler. The maker has said more will follow once a propeller prints successfully.



Project by KOKENSHA TECH. Watch it on their YouTube channel:

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Melting brass threaded inserts into the handle casing looks like the smartest single call in this build. Screwed joints in plain plastic strip out easily, while brass gives threads that hold up over repeated assembly. The trade-off is an extra step with a soldering iron, but the result is a handle that can be opened and closed again cleanly.

How did the maker route the soldered wiring inside the housing? With a battery compartment in the handle and a motor bracket elsewhere in the frame, I am curious whether the wires were trimmed to a set length before soldering, or tucked into place after the frame parts were screwed together.

Since the maker already wants to model and print a fan blade and motor shaft coupler later, my suggestion would be to try TPU for that first blade. A flexible material seems forgiving on a spinning part, and a softer first attempt fits the safety mindset behind keeping the original cardboard blade around a young child.

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