DIY PC Fan Air Purifier with Lights
If you want to combine quiet and effective air purification with a customizable light show, this is the DIY PC fan air purifier for you! The PC fan air purifier design described in this article is inspired by the “Healthy Glow” from cleanairkits.com, specifically when considering their tested fan configuration.
This is also the air purifier we built at two workshop(s) I hosted at the University of Waterloo, one of which was in collaboration with Ontario School Safety. You can check out an article about the student/faculty workshop at Waterloo written by the Centre for Bioengineering and Biotechnology media team. I have also uploaded a YouTube video (below) that walks through the components and assembly instructions.
The components used in this design create a durable build with minimal tape, but you will have a few spare components left over depending on how many air purifiers you build. For example, the Lian Li ST120 fans typically come in boxes of three, but you need four for one build. The press-fit fasteners come in packs of 75, but you only need 28. Etc. …
If you are in Canada, most components can be purchased from Amazon.ca or other Canadian outlets. The corner connection pieces are the most challenging to find. This design uses a custom order from a manufacturer in the USA. I will list some alternative corner connection pieces that you can try. I have not tried these alternatives, so proceed with caution (and creativity)!
Depending on any sales you might find, making one of these air purifiers could cost you around $400, and you will likely have four fans and some wiring left over. You could purchase extra components for a second smaller air purifier with the extra fans. You might be inspired by some of the other designs described on itsairborne.com for a 4-fan configuration!
Components List:
#1. Top/Bottom/Left/Right Side Pieces:
If you can access a laser cutter, you can cut these from acrylic, hardboard, and other materials. If you cannot access a laser cutter, corrugated plastic can be cut using the template dimensions with other tools. The dimensions of the included .dwg files below are in millimetres.
- Top Piece AutoCAD Drawing (643 x 177.8)
- Bottom Piece AutoCAD Drawing (643 x 177.8)
- Left Piece AutoCAD Drawing (393 x 177.8)
- Right Piece AutoCAD Drawing (393 x 177.8)
#2. 4 x Lian Li ST120 Fans
#3. 3 x Arctic P12 Fans
#4. 28 x Grill/Fan Fasteners:
There are several options available depending on the look you want. The Weatherstrip Fasteners are more expensive because you have to purchase them in bulk (i.e., 75/bag).
#5. 7 x Protective Fan Grill
#6. 2 x 3M 16x25x1 Inch MERV-13 Filters
Be careful about the actual dimensions of the filters, as the 3M filters used in this build allow for a very tight seal around the foam weatherstripping edges, resulting in minimal tape required. For example, Costco has their own 16x25x1 inch MERV-13 furnace filters, but the dimensions are slightly smaller than 3M’s, resulting in larger gaps given the dimensions of the side pieces. This can be fixed with thicker weatherstripping foam, as mentioned below.
#7. 4 x Corner Connector Pieces:
You must email their customer support team to request the 18-inch L-Connector (90 degrees) to be cut to a 7-inch length. While this component works well and creates a sturdy frame, it is not very accessible. I am considering simpler options for future designs. You could also purchase 16 pieces of the default length (1.875 inches) and glue/tape them together.
Note: This component is modified by removing 2 cm of the inner edge. Removing the inner edge helps keep the filter in place. I cut these with Wiss 9 3/4-inch Straight Snips.
Here are some alternative corner connection pieces:
- 1/8" x 90 Degree Corner Molding (Display Products Online — USA)
- Composite Inside Corner Trim (Home Depot — USA)
- PVC Inside Corner Edging (Home Hardware — Canada)
- Edge Protector PVC Wall Corner Shield (Amazon.ca — Canada) For these, you might want to purchase an inner and outer piece, cutting the outer piece to 7 inches and the inner piece to ~5.5 inches.
Note: The dimensions of these alternative corner connection pieces may differ from the ones from Displays &Holders. Depending on their differences, the side pieces may need to be modified to ensure a good fit.
#8. 1 x Power Supply
#9. 1 x Dual Serial to Power Cable
#10. 1 x PWM Fan Splitter Cable
#11. 2 x Rubber Bottom Pads
#12. Foam Insulation Tape:
Purchase this only once you know what thickness you need, as this may depend on the thickness of your side pieces and the size of your filter.
If using 3mm thick side pieces (e.g., acrylic, hardboard, medium density fibreboard, etc.):
- 164 inches of weather-stripping foam at 1/2 inch wide and 1/16 inch thick.
- You will likely need it on all sides of the box if using a 3M filter. For a Costco Kirkland filter, I would choose a thicker foam.
If using 4mm thick side pieces (e.g., corrugated plastic):
- 64 to 164 inches of weather-stripping foam at 1/2 inch wide and 1/4 inch thick.
- Depending on the filter size, you may only need it on the left and right sides of the box if using a 3M filter. For a Costco Kirkland filter, it may be needed on all sides.
#13. 2 Inch Thick Tape
Adding tape can be optional, depending on how well the filter fits within the frame. For example, if you notice large gaps between the weatherstripping foam and the filter frame, you can use Gaffer tape (or another type that doesn’t leave residue) to close those gaps.
Assembly Instructions:
You can watch my YouTube video or follow the steps in this slide presentation on my website (under the “Projects” section) to assemble the components into an air purifier.
Feel free to contact me with any questions or clarifications. You can find my contact details on my website.
Happy DIY air purifier building!
