Introduction
Hello guys, today I would like to share with you my SFF case concept that I have been working at on and off for the last year or so, In this post I will run through my concept, my first iterations of the design, and why they couldnt work, and finally where I am now with the design including renderings and specifications, and hopefully (in the next couple days!) I will have my hands on some 3d printed prototype parts and I can update this thread.
Why
First off, I want to explain breifly why design a case instead of buy one, there are loads of great cases on the market, some which I took inspiration from. I decided to design my own as I am an engineering student and wanted to take the oppertunity to try learn some CAD skills by doing something that I would enjoy and really just for a bit of fun, and after sticking with it whenever I had the time I now have something I would like to share and have feedback on.
Initial Concept
The idea for the case originally was soley based around the hardware that I currently own, primarily my AIO cooled GPU. Using tinkercad I mad a quick mock up of the various hardware componants of a pc, nothing fancy just plain boxes with the correct external dimensions, and using this I rearranged them in all the ways I could think of to try visualise optimal layouts and airflow ect.
From this I got the main idea of the case, using two 120mm AIO's, one for the gpu and one for the cpu, I could sandwhich them together between the two side pannels of the case, thus creating a single unrestricted airflow path from one side to the other. This idea while also utilising a sandwhich layput for the motherboard, except instead of the GPU behind the motherboard I would have the PSU behind the motherboard and the GPU under the motherboard. I attachted the original mockups below.
First Design Attempts
So with this initial concept I went about picking a CAD program and learning on the go, I will save you the details on the research ect I did on manufacturing and case design, but I decided to use Fusion 360 and its sheet metal design capanilities. So first thing first, I had to get accurate size specifications for all the componants so I could design to the right size have the correct cutout dimensions ect.
Issues
With my first try there was a lot left to be desired, the case was lacking in versatility, there was only one way for the componants, my way, and the various parts and bends of the design where far too complicated to manufacture for a reasonable price, in the render below you can see that the only layout option really is the one I made in mind, which of course wouldnt suit a whole lot of people. Along the top and bottom edges on the side there is cut outs for ball and stud fasteners for easy panel removal, and the top/front panel was screwed on at the back and bottom so that the screws wouldnt be visable. At the time I was very proud but I realise now that it wouldnt work.
New Ideas
So after this I decided that the case needed to be more versatile in the componant layout, and the vertical mount for the fan in the V1 attempt was how I would aim to achieve this, by putting this vertical fan mount on rail that runs horizontally along the case top and bottom, you can mount anything you want anywhere you want. With this Idea I iterated again. I also decided instead of trying to use complex sheet metal bends to support the sandwhich motherboard layout I would simply use a tabs on the front and rear panels of the case (Like the Ghost S1). This version instead of ball stud fasteners has cutouts for the lian li clips for the side and top pannels. Also once I started modeling this I found the rails too difficult to implement so went with a 240mm fan mount like the NCASE on either side of the case, with the intentions of being able to mount AIO's, PSU, HDD and SSD.
I did try Implement some of these changes in my V1 sheet metal design as you can see here:
I posted this on reddit a while back, included are different layout options as a collage.
Mock up
Using the V2 design I adapted some of the threaded holes ect and got it 3d printed, using black PETG and a company called RENND I got an excellent print, however having the design in person I realised that a lot of my supports for the vertical beams and the fan mount ect would be too flimsy and overall the design was a bust. However the physical object let me come up with new ideas and see what I could maybe improve, as well as give me a nice size comparison to my current S340 Elite tower. Pics below.
Current Design
So finally, the current design iteration. After leaving the design for a while due to exams ect, I came back to it with a fresh mind, and instead of attempting a sheet metal fabrication design I decided to try a design which would use CNC machining. So, I researched how to optimise designs for CNC and what was actually possible ect and started planning a new design, and after many starts and stops and throw aways I came up with the following.
Concept
The basic concept was to stay the same, sandwhich layout for the motherboard and rails for multiple mounting options on either side, after messing with some different designs I found that to cnc some sort of rail system would probably be too complicated and expensive so I opted to try aluminium extrusion or mitre tracks. I chose these as they are cheap and easily sourced. Problem is I couldnt find any small enough for what I wanted to do, for example your standard aluminium extrusion is 20*20mm in cross sectional dimensions which was far too much for my liking. I eventually came across specialised extrusion made by a company called makerbeam, their extrusion is 10mm*10mm in cross sectional dimension which is the exact size I was looking for, on their website they also sell all the neccessary t-slot bolts and nuts ect for their extrusion. So I made a quick 3d model of their extrusion profiles and brackets for use in my design.
The benefits of using this is that the rail system and the motherboard mounting hardware are now inherently modular as they are built on these linear tracks, also I would no longer need to model supports for a motherboard tray which reduces the complexity of the parts to be CNC'd. Furthermore the side panels and top panels can be mounted directly onto the extrusion also further simplifying and bringing down costs of the design.
Specifications
Ok. Finally. The specifications.
Renders
Here I have provided renders of my newest design in both silver and black colour, I didint render many different layouts as they are essentially the same as the layout options found in the V2 album.
Prototype
Currently waiting on the delivery of the extrusion profiles and the back and front peices 3D printed, Decided not to get the panels as they are not essential for test fitting ect. I will update this with pictures and thoughts when they arrive.
Further Ideas/Changes
The two current Ideas I have that I would like to see implemented, is firstly to have the motherboard tray movable, by being able to move it forwards you could increase the space behind it for drives and cooling ect as the heigh of an AIO on the CPU would not be very high, or you could move it backwards decreasing the space behind it allowing for larger air coolers as not everyone has an AIO or wants to use one.
The other idea, is that the space behind the motherboard currently is very large, inface its large enough to fit a 3 slot GPU, I know my case has limitations because of the GPU position, however with the additions of a bracket that mounts to the rails or extra PCIE cutouts, the option for the 2 slot GPU at the bottom or a 3 slot behind the motherboard would add a lot more versatility to the case imo.
Conclusion
If you read this far I really appreciate it, I would love some thoughts and feedback on this project, or if there is anymore information or viewing angles of the models ect that you want then just let me know! Thanks guys
3D Printed Prototype Build
3D print prototype
Build Using Concept parts
Finished Prototype Build
Hello guys, today I would like to share with you my SFF case concept that I have been working at on and off for the last year or so, In this post I will run through my concept, my first iterations of the design, and why they couldnt work, and finally where I am now with the design including renderings and specifications, and hopefully (in the next couple days!) I will have my hands on some 3d printed prototype parts and I can update this thread.
Why
First off, I want to explain breifly why design a case instead of buy one, there are loads of great cases on the market, some which I took inspiration from. I decided to design my own as I am an engineering student and wanted to take the oppertunity to try learn some CAD skills by doing something that I would enjoy and really just for a bit of fun, and after sticking with it whenever I had the time I now have something I would like to share and have feedback on.
Initial Concept
The idea for the case originally was soley based around the hardware that I currently own, primarily my AIO cooled GPU. Using tinkercad I mad a quick mock up of the various hardware componants of a pc, nothing fancy just plain boxes with the correct external dimensions, and using this I rearranged them in all the ways I could think of to try visualise optimal layouts and airflow ect.
From this I got the main idea of the case, using two 120mm AIO's, one for the gpu and one for the cpu, I could sandwhich them together between the two side pannels of the case, thus creating a single unrestricted airflow path from one side to the other. This idea while also utilising a sandwhich layput for the motherboard, except instead of the GPU behind the motherboard I would have the PSU behind the motherboard and the GPU under the motherboard. I attachted the original mockups below.
First Design Attempts
So with this initial concept I went about picking a CAD program and learning on the go, I will save you the details on the research ect I did on manufacturing and case design, but I decided to use Fusion 360 and its sheet metal design capanilities. So first thing first, I had to get accurate size specifications for all the componants so I could design to the right size have the correct cutout dimensions ect.
Issues
With my first try there was a lot left to be desired, the case was lacking in versatility, there was only one way for the componants, my way, and the various parts and bends of the design where far too complicated to manufacture for a reasonable price, in the render below you can see that the only layout option really is the one I made in mind, which of course wouldnt suit a whole lot of people. Along the top and bottom edges on the side there is cut outs for ball and stud fasteners for easy panel removal, and the top/front panel was screwed on at the back and bottom so that the screws wouldnt be visable. At the time I was very proud but I realise now that it wouldnt work.
New Ideas
So after this I decided that the case needed to be more versatile in the componant layout, and the vertical mount for the fan in the V1 attempt was how I would aim to achieve this, by putting this vertical fan mount on rail that runs horizontally along the case top and bottom, you can mount anything you want anywhere you want. With this Idea I iterated again. I also decided instead of trying to use complex sheet metal bends to support the sandwhich motherboard layout I would simply use a tabs on the front and rear panels of the case (Like the Ghost S1). This version instead of ball stud fasteners has cutouts for the lian li clips for the side and top pannels. Also once I started modeling this I found the rails too difficult to implement so went with a 240mm fan mount like the NCASE on either side of the case, with the intentions of being able to mount AIO's, PSU, HDD and SSD.
I did try Implement some of these changes in my V1 sheet metal design as you can see here:
Mock up
Using the V2 design I adapted some of the threaded holes ect and got it 3d printed, using black PETG and a company called RENND I got an excellent print, however having the design in person I realised that a lot of my supports for the vertical beams and the fan mount ect would be too flimsy and overall the design was a bust. However the physical object let me come up with new ideas and see what I could maybe improve, as well as give me a nice size comparison to my current S340 Elite tower. Pics below.
Current Design
So finally, the current design iteration. After leaving the design for a while due to exams ect, I came back to it with a fresh mind, and instead of attempting a sheet metal fabrication design I decided to try a design which would use CNC machining. So, I researched how to optimise designs for CNC and what was actually possible ect and started planning a new design, and after many starts and stops and throw aways I came up with the following.
Concept
The basic concept was to stay the same, sandwhich layout for the motherboard and rails for multiple mounting options on either side, after messing with some different designs I found that to cnc some sort of rail system would probably be too complicated and expensive so I opted to try aluminium extrusion or mitre tracks. I chose these as they are cheap and easily sourced. Problem is I couldnt find any small enough for what I wanted to do, for example your standard aluminium extrusion is 20*20mm in cross sectional dimensions which was far too much for my liking. I eventually came across specialised extrusion made by a company called makerbeam, their extrusion is 10mm*10mm in cross sectional dimension which is the exact size I was looking for, on their website they also sell all the neccessary t-slot bolts and nuts ect for their extrusion. So I made a quick 3d model of their extrusion profiles and brackets for use in my design.
The benefits of using this is that the rail system and the motherboard mounting hardware are now inherently modular as they are built on these linear tracks, also I would no longer need to model supports for a motherboard tray which reduces the complexity of the parts to be CNC'd. Furthermore the side panels and top panels can be mounted directly onto the extrusion also further simplifying and bringing down costs of the design.
Specifications
Ok. Finally. The specifications.
| Parameter | Specification |
|---|---|
| Case Dimensions | 230 (H) x 150 (W) x 300 (L) mm |
| Case Volume | 10.35 L |
| Graphics Card | Dual Slot, reference height up to 290mm in length |
| Motherboard | Mini-ITX |
| Power Supply | SFX or SFX-L |
| Drives | 4 x HDD/SSD if no AIO's mounted |
| CPU cooler heigh clearance | 65mm |
| AIO Support | 1 x 240mm AIO (width including fan = 70mm) or 2 x 120mm AIO or 1 x 120mm and 1 x 140mm |
| Front Ports | None yet but I was thinking USB Type C?? |
| Power Button | Anti-Vandal switch, can be easily changed in future |
Renders
Here I have provided renders of my newest design in both silver and black colour, I didint render many different layouts as they are essentially the same as the layout options found in the V2 album.
Prototype
Currently waiting on the delivery of the extrusion profiles and the back and front peices 3D printed, Decided not to get the panels as they are not essential for test fitting ect. I will update this with pictures and thoughts when they arrive.
Further Ideas/Changes
The two current Ideas I have that I would like to see implemented, is firstly to have the motherboard tray movable, by being able to move it forwards you could increase the space behind it for drives and cooling ect as the heigh of an AIO on the CPU would not be very high, or you could move it backwards decreasing the space behind it allowing for larger air coolers as not everyone has an AIO or wants to use one.
The other idea, is that the space behind the motherboard currently is very large, inface its large enough to fit a 3 slot GPU, I know my case has limitations because of the GPU position, however with the additions of a bracket that mounts to the rails or extra PCIE cutouts, the option for the 2 slot GPU at the bottom or a 3 slot behind the motherboard would add a lot more versatility to the case imo.
Conclusion
If you read this far I really appreciate it, I would love some thoughts and feedback on this project, or if there is anymore information or viewing angles of the models ect that you want then just let me know! Thanks guys
3D Printed Prototype Build
3D print prototype
Build Using Concept parts
Finished Prototype Build
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