FDM Cooling Vent 

On day two I came back and checked the fit of the first prototype. It slotted into the vent well, but missed the mark on the alignment of some holes. I cut the required space out manually drew up a part to fix the hole I made. The cost of material is high and I wanted to use as little as possible.

This first version had the legs seen below this curve. My client asked me to include them for the stabilization of the prototype but they were not needed given the tight fit of the vent. I designed the interfacing connection with a slight draft to cover up any sloppiness in my measurement and ensure a solid connection.

I designed the vent in to parts to fit in the printers I had access to. The first part would slot into the AC unit and the second part would extend up to the grate. I made the second part two lines of filament thick so I could cut it to size on location with a small bring a single line thick on the top. 

Previously I designed the upward vent to be one line of filament thick but when air came through it rattling occurred. A two line thick upward vent eliminated the rattling. 

On day three I installed the final version of the parts. I cut each of the parts to size and wedged the slots into the ac units. Install took all of 30 minutes and my clients loved the results. I sent them the files and thanked them for the work. A month later I checked in and everything is still working beautifully. 

All and all, I only had to bill them for 10 hours of work.