A smooth surface duct allows for optimum airflow. For best results, use galvanized sheet metal or possibly PVC. Flexible aluminum duct is durable, easy to install and often used. However, the ridges in aluminum flexible duct increase static pressure and can reduce air flow and fan performance. This results in lower CFMs, higher noise levels and greater energy consumption. The degree to which performance is affected depends on the length of duct, number and degree of elbows.

Sagging or weaving a fan duct will also increase static pressure and reduce a fans performance. When using a flexible aluminum duct, support the entire length of the duct with braces or hangers to keep it as straight as possible for the entire run. If the duct lies across the attic, do not allow it to sag between each joist. Also, avoid weaving serpentine through trusses.

Using dryer duct connectors made of nylon or vinyl is not recommended due to high static pressure caused by its ridges and curvature. Insulated flexible duct must be fully extended to avoid added resistance.