Dewalt 611 Airflow Diverter

I did a little re-work of @MathesonHarris 3D model (who re-did yours). I made mine so that you can re-use the screws that come on the DeWalt by countersinking the holes. I also made the LED holes larger so that it has more light showing and finally I cut the back off so that it was easier to get to the Lock button.

You can download and print yourself.

You can also modify it if you want by going to and signing up for a free account. Do a search for the “DeWalt 611 Air Diffuser”


@MartyEnerson That looks great! Question as I am not a 3D printer and send my files out to get printed, do you foresee any melting issues when using PLA filament? I would think the router would provide enough cooling with the amount of air its chucking but not sure.


As long as the PLA or ABS is not touching any moving parts, it stays cool. You can grab onto the aluminum housing and it stays cool even after running for awhile.

If you want, I could print one out and send it to you… (you cover the cost of mailing)


I just had one of these printed by a local printer ( - I look forward to installing it, just the next step in the battle with dust. I will provide feedback as to it’s effectiveness once installed.

Thanks for sharing the file!

I designed several of these from scratch although they all look fairly similar, of course. I specifically wanted open ended slots for the LEDs to maximize the light out and I printed them in white to reflect light.

The smallest is 66mm in diameter, the same as the router, so that it will fit through the 611 router mount without being removed.

Then I designed one that is 90mm in diameter so that it would maximize the area to divert the air. Maybe not an absolute necessity but useful for those people that are never going to remove the router.

Then I designed one to hold a SuperEyes microscope to use for spotting and centering, also mostly 90mm in diameter.

I’m planning on putting these in an online store as soon as I figure out how to use Weebly and if that doesn’t work, then I’ll change to Shopify. It is going a little slowly as I’m an engineer, not an online sales and marketing guru.

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I updated my diffuser with fins. You download the .stl here.


What advantage do the fins add? I printed your V1


If you look at the bottom of the DeWalt, you will see that there are fins in the metal casing to direct air. I assume that DeWalt is doing this for a reason so I just added it to mine. They probably have smarter people engineering things than me.

All in all, it probably will have zero effect on anything compared to my V1.

One thing I did on V2 is I raised up the two side pieces where the LEDs shine through. Now they are touching the case which helps with the light bleeding out. Maybe I will update my V1 to have this also.

If anyone wants one of my version 1’s, I have a green PLA one that you can have… just pay for shipping.

Id like to try it out, message me to set it up. Toledo, Ohio shipping. Thanks#

Hey, thanks for the handy 3D printable file, Marty, saved me having to go back and re-model it myself. I’m going to have to print one of these out this evening, I think.

I came up with this… I used the clip you remove from new router on the bottom, attached a piece of green acrylic. A circle… 3" with a 7/8" hole. Drilled in a few slots on my vaccum side and glued it together, threaded it on, and it looks Fawesome, if nothing else, Im concerned about heat dispersal however. Thoughts?

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20151111_080120.mp4 (839.2 KB)
It works, pretty well too! I love my x carve. I need a dust boot on this setup, if someone had any ideas.

Maybe cut out some of those square shaped sections in the end of it, allowing the air to blow out the sides. I’d be surprised if this airflow isn’t needed to keep the bearings cool and assist with cooling the router internals.

I’ve thought of doing something similar, however with a dust skirt in place and dust shields along the rails when needed, I’m quite happy to keep the air flowing downwards into the cut and assisting in keeping the toolpath clear.

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That is the main reason for that Air Blow. Never think about cutting that off. I’m not smarter that designing engineers. All I know is, generating great Air flow inside my dust shoe, cleaning all cut path. :relaxed:

Made my own today thanks for this!!


Thanks for sharing the dxf file. I made my diffuser this morning, after tweaking the design dimensions slightly, and it has improved the dust collection more than I had thought it might.

I currently use a Kent CNC dust shoe and before adding the diffuser the downdraft from the DeWalt spindle/router blew chips and dust all over the place (inside the shoe itself), hampering the shop-vac’s ability to such it up. Now it appears that chips and dust head straight toward the suction. Here are a couple of pics and a short video of the diffuser in place. You may just see the chips from the HDPE material heading straight for the suction. Thanks for sharing!


Can you share the files or project with your mods , did u use the factory screws ?

Hi FatKatOne, I removed the factory screws which hold the spindle locking mechanism and tapped the holes to take an M4 thread. The screws I used were countersunk 20mm M4 Hex, which worked perfectly with the material I was using, which was 12.7mm thick HDPE. I modified the dxf file in Adobe Illustrator, then used VCarve to create the tool paths. I have attached the Adobe Illustrator file, my version of the dxf file, the VCarve file and the resulting Gcode…

diffuser_basic.gcode (419.2 KB)
diffuser_basic.crv (1000.5 KB) (1.3 MB)
diffuser_basic.dxf (62.2 KB)


Awesome thanks !

Made one out of 1/2" MDF next will be on plastic