Handheld Server Fan
You know PC fans? THOSE ARE WEAK!! You know what boiling CPU on servers use? SERVER FANS, THE NAME SAYS IT ALL!!! SERVER FANS ARE MADE TO COOL DOWN SERVERS WHICH IF OTHERWISE WOULD BE BOILING WATER IF YOU DON'T PUT A SUPER POWERFUL FAN IN THEM! You wanna know what if feels like to hold them and FEEL THEIR POWER??? THIS IS YOUR SOLUTION!!
Created by
AtlaGenesis
Tier 4
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AtlaGenesis
added to the journal ago
Redesigning
After a brief moment of thinking, I have now decided that I won't be using AVC Taiwan 8025 fan for this project, but rather a more powerful and a more well known server fan of 4056 models, AKA the San Ace 40!! What makes this fan special is that this fan packs a lot of power into such a small body, and because this model in specific is counter rotating, it creates a beam of wind instead of vortex spiraling cone of wind, and generates a higher static pressure.
it also draws a higher current, around 1.8A per fan, 3.6A total, well yeah this is obviously too high for the XL6009 step up converter, so what I will do is to just get rid of the boost converter and use direct connection from the battery, this way the wirings are less complicated, and it provides as much amps as it needs while lowering the voltage to lower the fan consumption, even that is already really powerful, and with a very fast spinny thingy you need a fan grill
which here you can see has a vortex pattern for the vibe, I've also filetted it so it wouldn't break if you press your fingers on it (which you shouldn't anyways)
I have spent a few hours redesigning and rethinking about how do I improve it, with a total of... who knows, 4? 3? I'm faster than in the past
AtlaGenesis
added to the journal ago
I redesigned the bracket
This is the Bracket that's renewed, better, it's simpler, it fits well, it uses only screws and nuts, no heat inserts, I figured that this design would make it look cleaner, and in the future I can even integrate the bracket mounting design for other fans incase I'm bored with the 8025, it takes way less space, way less supports.
here is when it's assembled, the screw will go through the holes, and you screw the nuts on the inside, it's also cheaper than using brass heat inserts and are not invasive, I redesigned the bracket in ~3 hours, it's much faster.
I also updated the BOM cuz of that, researching on some stuffs, and iterating some things, putting the new files together takes abt 20 mins
AtlaGenesis
added to the journal ago
MODELLED THE NOZZLE, THE FAN BRACKET AND OTHER CHANGES!!
AHHH FINALLY!!! IT'S DONE!!!
To be honest, this might have been the fastest modelling work I have ever done, for a whole project ofcourse...
and ofcourse I forgot to publish the previous journal, in this journal I have improved some structural integrity or strength or whatever by adding fillets! I just know that you can actually use fillets to ADD to edges, and not just SUBTRACT them, it's a pretty quick modelling, i just did some revision on how do I do the fan bracket and now have come to a final decision to use screws... and not sliding mechanism because screws just have better strength overall... also I would like to use those JST XH connectors as they are quick and also quite secure
AtlaGenesis
added to the journal ago
Modelled the fan grill
A simple 1.5mm thick fan grill, 5mm hole for screws, 71.5mm apart, 80x80mm, 1 modelled it using 3 sketch layer and it's pretty quick, I'm going to make 2 of these so you can... well be protected...
AtlaGenesis
added to the journal ago
modelling the handle and making sure everything fits
just a quick modelling of the handle, and putting all of the modules, the batteries, and also making clearance for the wires and incase of some things, after this I'm going to make some attachments for the fan, like a plastic grill, and a nozzle (so you can focus the airflow for BBQ
AtlaGenesis
added to the journal ago
Parts LIST!!!
here I have all of the parts to make this handheld server fan on github, it is way simpler than my previous fan... and I design this to have a lot of battery life, powerful and also slim so that you can actually bring it around in your backpack for travelling
AtlaGenesis
started Handheld Server Fan ago
2/7/2026 - Parts LIST!!!
here I have all of the parts to make this handheld server fan on github, it is way simpler than my previous fan... and I design this to have a lot of battery life, powerful and also slim so that you can actually bring it around in your backpack for travelling
2/8/2026 - modelling the handle and making sure everything fits
just a quick modelling of the handle, and putting all of the modules, the batteries, and also making clearance for the wires and incase of some things, after this I'm going to make some attachments for the fan, like a plastic grill, and a nozzle (so you can focus the airflow for BBQ
2/10/2026 - Modelled the fan grill
A simple 1.5mm thick fan grill, 5mm hole for screws, 71.5mm apart, 80x80mm, 1 modelled it using 3 sketch layer and it's pretty quick, I'm going to make 2 of these so you can... well be protected...
2/11/2026 - MODELLED THE NOZZLE, THE FAN BRACKET AND OTHER CHANGES!!
AHHH FINALLY!!! IT'S DONE!!!
To be honest, this might have been the fastest modelling work I have ever done, for a whole project ofcourse...
and ofcourse I forgot to publish the previous journal, in this journal I have improved some structural integrity or strength or whatever by adding fillets! I just know that you can actually use fillets to ADD to edges, and not just SUBTRACT them, it's a pretty quick modelling, i just did some revision on how do I do the fan bracket and now have come to a final decision to use screws... and not sliding mechanism because screws just have better strength overall... also I would like to use those JST XH connectors as they are quick and also quite secure
2/16/2026 - I redesigned the bracket
This is the Bracket that's renewed, better, it's simpler, it fits well, it uses only screws and nuts, no heat inserts, I figured that this design would make it look cleaner, and in the future I can even integrate the bracket mounting design for other fans incase I'm bored with the 8025, it takes way less space, way less supports.
here is when it's assembled, the screw will go through the holes, and you screw the nuts on the inside, it's also cheaper than using brass heat inserts and are not invasive, I redesigned the bracket in ~3 hours, it's much faster.
I also updated the BOM cuz of that, researching on some stuffs, and iterating some things, putting the new files together takes abt 20 mins
3/16/2026 - Redesigning
After a brief moment of thinking, I have now decided that I won't be using AVC Taiwan 8025 fan for this project, but rather a more powerful and a more well known server fan of 4056 models, AKA the San Ace 40!! What makes this fan special is that this fan packs a lot of power into such a small body, and because this model in specific is counter rotating, it creates a beam of wind instead of vortex spiraling cone of wind, and generates a higher static pressure.
it also draws a higher current, around 1.8A per fan, 3.6A total, well yeah this is obviously too high for the XL6009 step up converter, so what I will do is to just get rid of the boost converter and use direct connection from the battery, this way the wirings are less complicated, and it provides as much amps as it needs while lowering the voltage to lower the fan consumption, even that is already really powerful, and with a very fast spinny thingy you need a fan grill
which here you can see has a vortex pattern for the vibe, I've also filetted it so it wouldn't break if you press your fingers on it (which you shouldn't anyways)
I have spent a few hours redesigning and rethinking about how do I improve it, with a total of... who knows, 4? 3? I'm faster than in the past