Despite its compact size, the Raspberry Pi Zero 2W with a quad-core CPU boasts impressive performance. However, if the heat dissipation is insufficient, its CPU will automatically reduce its frequency when the temperature reaches about 80°C to prevent overheating: [https://raspberrytips.com/raspberry-pi-temperature/]

This fan assembly can help you maximize the performance of the Raspberry Pi Zero 2W—especially when operating in high environmental temperatures or overclocking the device, the effect is particularly noticeable. This solution is also suitable for the Raspberry Pi Zero W and Raspberry Pi Zero.

Compared to my previous design [https://www.thingiverse.com/thing:6500953], this new design has seen significant improvements. It includes several Python scripts that can monitor and precisely regulate CPU temperature in real time. To control the on-off operation of two-wire fans using the Python script fan.py, you need to have a certain level of knowledge in electronic circuits and soldering skills. However, due to hardware and software limitations, it currently does not support the use of variable-speed three-wire fans.

In the previous design, the rear part of the fan motor would block some of the heat sinks, thus weakening the overall heat dissipation effect. However, the optimized design can more efficiently guide the fan airflow, fully covering the heat dissipation area of the Zero CPU, significantly improving the heat dissipation efficiency.

In the printout, there is a place where additional support columns need to be installed

I've also specially introduced two versions of front brackets - Model 3 and Model 3A. Unlike the traditional screw-fixing method, these two brackets only need to be gently pushed into the GPIO pins, without having to fix them on the PCB through the Raspberry Pi's mounting holes. However, this design also brings a slight inconvenience: some GPIO pins will be obscured and cannot be directly accessed. Model 3 and Model 3A brackets are designed for different models of Raspberry Pi, and the obscured GPIO pins vary accordingly. Users can

In addition to the Raspberry Pi Zero itself and various printables, you also need to prepare the following accessories:

• A universal heat sink with dimensions of 14/18×13×6 mm, which comes with a double-sided thermal conductive tape on the back. An example of such a product can be found at [https://en.aliexpress.com/item/4000515928855.html]. Different models of Raspberry Pi Zero often have slight differences in the position of the CPU, which is typically off by one or two millimeters. Therefore, when installing the heat sink, you need to make appropriate adjustments to its position based on your Raspberry Pi model and the location of the en
• A high-speed, two-wire fan powered by 5V, with dimensions of 20×20×10 mm. For example, this powerful fan with a speed of up to 15,000 RPM: [https://en.aliexpress.com/item/1005002554588949]. If the fan becomes excessively noisy after prolonged use
• Three M2.5×16 mm screws are used to fix the fan between the two brackets.
• Two M2.5×8 mm screws and two M2.5 nuts are used to securely fix the entire fan assembly on the Raspberry Pi Zero.

The diameter of the installation holes on the printouts is divided into two types: 2.5 mm and 2.0 mm. The 2.5 mm holes are designed for directly inserting M2.5 screws, while the 2.0 mm holes are suitable for allowing the M2.5 screws to self-tap and firmly embed when they are first inserted. For the correct method of inserting the screws, please refer to the relevant picture instructions.

As always, I have attached the OpenSCAD source files for you, so that you can carry out secondary development or optimize and improve it according to your needs:

• Please download and install OpenSCAD from [https://www.openscad.org].
• Launch OpenSCAD and open the attached OpenSCAD source file
• You can modify the various parameters at the top of the file, and even make direct adjustments to the code.
• Save the changes
• Render design
• Export the rendered design to formats such as .stl file
• Carry out the slicing process and start printing.

For more of my design works, please visit:
https://www.thingiverse.com/thinger13/designs