Printed Centrifugal Dust Separator Stays On Budget

January 17, 2024 by Maya Posch 24 Comments

Anyone who’s ever spent time in a woodworking shop knows how much dust is produced when cutting, sanding, and so on. [Tim] of Pilson Guitars was looking to outfit his shop with centrifugal dust separators to combat the problem, which are supposed to remove over 99% of the sawdust particles right out of the air. Unfortunately, they can cost thousands of dollars. So he decided to try making his own.

Centrifugal dust separator design, by Tim at Pilson Guitars.

Using a clear PVC tube and 100 hours of printing on his Prusa i3 MK3, his CAD file had come to life, ready to use the power of centrifugal air to leave just enough fine dust in the output port to have a HEPA filter handle the remainder. Unfortunately, initial testing showed that a single dust separator filtered out far less than 90%, and even adding a second unit bumped that up to only 94.2%. Still impressive, but this would clog up a HEPA filter in no time. Thus [Tim] had a second try at it, after a range of helpful comments to the first video.

Changes included a different design for the impeller blades to improve the vortex, as well as attempting to run the system in series. Sadly more issues cropped up, with apparently the air also seeking a way via the collection bins that has [Tim] rethinking more aspects of the design. He has made the design files (STEP and more) available on GitHub for perusal by the community and hopefully some constructive input on how to DIY such dust separation system.

Over the years, we’ve seen many different approaches to the problem of dust collection. We’ve covered other 3D printed solutions if your printer is looking for something to do, but if you’d prefer something a little more low-tech, this traffic cone dust separator is particularly clever.

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Two-Stage Dust Collector Recycles Blasting Media

November 30, 2021 by Tom Nardi 4 Comments

A critical element of a good blasting cabinet setup is a vacuum system that can suck out the dust, blasting media, and bits of removed material faster than it collects inside the chamber. A cyclone separator can get the job done, but since it dumps all the waste from the cabinet into one bucket, it can make reusing the blasting material a dirty job. But as [Daniel Bauen] explains in the latest Engineerable video, his two-stage dust collector is able to keep the cabinet clear while separating the used blasting material into its own container.

The cheap dust separator only works on large particles.

Basically, the idea here is to to use two different cyclone separators: one that’s very effective, and a cheap model that’s only able to remove large particulates. By running the air from the cabinet through the cheap separator first, the used blasting media is captured in a dedicated bucket. From there, the air runs through the high-efficiency separator to extract the finer dust. Finally, the shop vacuum [Daniel] is using has its own washable HEPA filter to catch anything that makes it through the two extractors; though he notes that it only rarely needs to be cleaned out.

Normally this system is attached directly to the blasting cabinet, and it does a good job of capturing the bulk of the used blasting media in real-time. But to make sure the media is really cleaned up being using it again, [Daniel] will actually run the contents of the first bucket through the system a few more times to separate out any of the more stubborn dust that might be mixed in.

Of course not everyone has the space, or even the need, for such an elaborate blasting setup. If you’re just trying to quickly clean up some parts on the cheap, you can make a basic blaster for around $6. Good luck capturing the media though.

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DIY Dust Cyclone A Traffic Cop Would Be Proud Of

April 26, 2015 by Rich Bremer 45 Comments

Sure, having a wood shop is super handy but it also can get real dusty. Hooking up a shop vac to suck up dust coming off a wood-cutting machine works for all of 3 minutes before the vacuum’s filter gets clogged with dust. There is a solution, though, and it is called a dust separator.

A dust separator does just as its name suggests, it separates dust from air. There is a common type of dust separator made in the DIY community, it has a cone-shaped body and is generally referred to as a cyclone-style. [Dror] built his own cyclonic dust collector out of an odd object… a traffic cone. Looking at it now, we wonder why this isn’t much more common!

The dusty air enters the PVC pipe and ends up spinning around the inside of the cone. Since the dust particles have mass, they are thrown to the outside of this chamber as they spin. They lose speed and drop down into the 5 gallon bucket below. The dust-free air then outlets through the top of the dust separator which is connected to a shop vac.

You’ll notice that [Dror] decided to use threaded rod to hold his separator pieces together. While this may seem like overkill, he had tried several glues and could not get any to stick to the traffic cone!

If you’d like to get in on the dust separator action but don’t have a traffic cone, they can also be 3D printed or made from metal.

3D Printed Cyclone Dust Separator

April 10, 2014 by James Hobson 17 Comments

DSCN7011

[Nicholas] has been reading Hackaday for a few months now, and after seeing several people’s dust extractor setups, he decided to make his own 3D printed version. And he’s sharing the files with everyone!

He has a small Lobo mill which produces a lot of dust and to clean up he’s been using a small “Shark” brand vacuum cleaner. It’s a powerful little thing, but has little to no capacity which makes it rather frustrating to use. This makes it a perfect candidate for a cyclone upgrade! If you’re not familiar with cyclonic separator it’s a way of removing dust from air using vortex separation — between rotational forces and gravity, this keeps the dust out of your vacuum cleaner and means you never need to change another filter!

Using Autodesk inventor he designed this 4-stage cyclone separator. It’s made for a 1.75″ OD vacuum hose (the Shark standard) but could be easily modified for different vacuums. We’ve seen lots of cyclone separators before, but this 3D printed one certainly makes it easier to fabricate to exacting standards!

Beer Mini-kegs Turned Into A Cyclonic Dust Collector

February 7, 2012 by Mike Szczys 19 Comments

[Darrell] made his own cyclonic dust separator which connects to a shop vac. We’re amused by his poke at Dyson’s marketing machine where he mentions that the ads say it took years to perfect those vacuum cleaners and he managed to put his together in a few hours…. from trash/recyclables no less!

Two mini-kegs are used as the separating vessel. The only other parts are some PVC plumbing fittings which help to direct the air and give him a way to attach the collector to the shop vac. The top keg is where all of the magic happens. Air and debris is sucked in through the hose coming in the side wall. A 45 degree elbow directs it downward and to the side, which starts the cyclonic action. The shop vac is attached to the tube in the top, with a cylinder extending into the keg. The spinning air must make a sharp turn to get into that cylinder; it’s at this point the debris drops out into the lower keg. See for yourself in the clip after the break.

This isn’t the first time we’ve seen dust collectors that use this concept. [Darrell] pointed out this one made out of plastic cups, and this other made from a 5-gallon bucket.

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