I’ve been working on a simple solution to quiet down my Supermicro SC219 based server. So I created a drop-in replacement for the original FAN-0126L4 hot-swap fan modules, which can be very loud at high RPM.
This model was designed to house Noctua’s NF-A8 PWM fans but other 80mm fans with 25mm thickness should also work. If you want to use fans of different thicknesses (>15mm), the frame can easily be adapted by changing a single variable in the CAD model.
Printing Details:
The frames should be printed using SLA or SLS. Some of the thin structures include overhangs which will be difficult to print using FFF.
I got the frames printed in PA at JLC3DP via SLS because of its toughness and heat resistance. This is an affordable option at under $5 per fan frame.
Assembly:
I shortened the cables of the noctua fans and crimped on new connectors (Molex 0008550102) but reused the original housing.
Next I had to cut the tab in the middle of the connector with a shorp knife to prevent interferences.
After removing the silicon isolators I used the included screws to attached the NF-A8’s to the frames.
You can access the CAD model here (Onshape):