540 mm Window Fan Sill & Beam Clamp Brackets (left sill + right beam)

Create a 3D-printable PLA bracket for mounting a 540 × 540 × 116.59 mm square box fan in a window. Follow the supplied reference drawing for the geometry and orientation. Make the bracket a rigid stepped clamp with a deep fan-receiving channel. The fan should slide approximately 116 mm into the channel. Add a flexible snap finger at the channel opening that flexes over the fan during insertion and snaps back to retain it. The rigid channel supports the fan's weight; the snap finger only retains it. Use rounded lead-ins and generous fillets at the snap root. Use approximately 0.3 mm fit clearance for PLA. LEFT SILL CLAMP: The wooden sill has a stepped profile: A=16.08 mm, A2=8.00 mm, B=57.57 mm, C=48.00 mm, D=9.74 mm, E=32.65 mm. Clamp around BOTH sill surfaces rather than only the first one. The first surface is B=57.57 mm and the second extends to B+D=67.31 mm. Reproduce the 8 mm A2 step between them. Make the clamp follow the stepped wooden profile securely. RIGHT BEAM CLAMP: Clamp onto the vertical middle wooden beam. G=61.64 mm and H=12.60 mm. The fan's edge extends 25 mm beyond the relevant face of this beam, so offset the fan-receiving channel 25 mm relative to the beam clamp. This is a positional offset, not a 25 mm gap. Create two complementary brackets: one for the stepped sill and one for the vertical beam. Their fan-receiving channels must align so they hold the same fan in the same plane. No screws or hardware. Optimize the geometry for FDM printing in PLA.

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