Final Pics of the three consoles that I made in the end. Scroll to Page 4 for more Final Pics!
-------------------------------------------------------------
Hello everyone - Welcome to my build log for my current project, a scratch-built PC / Games Console designed for the living room.
About the Build:
After my previous project was primarily built from used components and recovered materials, I wanted to design and build something new and bespoke, with materials sourced for the purpose of the build. The move to smaller cases and living room PC's was also an area that I've found really interesting recently; lots of great designs from both big manufacturers and modders alike. So this is my attempt at the same challenge. I'll be including as much of the design process as I can, as well as the actual building (the design phases pre-build were very important!)
The Build Spec - Primary Requirements:
- Powerful enough to play games and compete with other living room systems
- Small enough to fit in a unit under the TV and not look out of place (i.e. flat)
- Quiet enough that it doesn't ruin the gaming/TV experience
- The design must represent a visual showcase, one that provides Diesel Engine with a unique and clear identity.
Secondary requirements:
- The software must boot directly into a gamepad-navigable state. No Keyboard + Mouse
- The case must not light up like the sun (this is very distracting when sitting under the TV)
- The case should not use or require any specialist or custom hardware
- Be able to support both 1080p and 4K system setups
- Not require an external power brick
Oh... (and this should go without saying) but the build shall not call itself an "ITX case" and still support full size ATX hardware and all the trimmings.
Concept Artwork
I drew and modelled a range of concept pieces first, free from any technical limitations, just so I could see where the art style was heading. Once the style was chosen, only then would I start to figure out if the design was technically feasible.
A similar half and half design to the Xbox One and PS4, which have matt and gloss surfaces.
A chunky hexagonal design in copper plate also sounded great
A very slim, long and simple design. Minimising or hiding all controls and inputs from the front
I explored some of the same shapes and colours in 3D, using Sketchup to create some quick and dirty mockups
By this point I was aware of the size of ITX and SFF components and had a rough case size in mind.
This helped me work with some units when modelling
Technical Design
I decided to pursue and modify Concept 2#, it was a simpler design and there were areas of Concept 1# would be technically more difficult to implement. I needed to determine what parts of the design were feasible and the layout of the components within the case. There were three main parts of the design up for negotiation: orientation of the graphics card, form factor of the power supply, choice of supported components and airflow solutions.
It's worth mentioning here that I had also started investigating materials and fixtures. Like many cases, sheet steel construction would provide the strength and simplicity that I required for the inner shell. I planned on using premium materials to cover the steel shell and where possible, be fixed from the inside of the case so that no screws would be on show. My technical designs started to consider how the pieces would be made from bent sheel material and fit together.
I had experience using graphics card riser cables, so I knew that I would be able to re-orientate the card how I liked. Many other HTPC cases that I had seen use rigid risers and have the card fan facing downwards. I really didn't want this, it was important that performance cards get fresh air from outside the case so I wanted the fan to be as close to the console lid as possible. I planned to incorporate a design into the lid that provided direct airflow to the components.
I built a bunch of scale models to check the real-size of components. SFX and Flex ATX power supplies here.
I'd recommend this technique since 3D models can sometimes detach you from the relative size of objects.
An ITX motherboard and a SFX/short graphics card.
Side note: the questionable meatballs are NOT mine
I chose the Flex ATX form factor for its tiny height, just 40mm! The SFX power supplies were around 80mm and up. I started modelling and worked on translating my concept designs into a technical design
I decided the simplest layout of positioning the components next to each other would allow me to keep the case in a flat console style.
I explored a bunch of different front port options
Investigating ways that the Graphics car mounting would work in the simplest way
I started mapping the mounting holes for Flex ATX PSUs
The front panel assembly for the USB's + power button was something that I would have to create.
This was an early solution I came up with.
The tolerances were going to be tight. I learned that folding very near holes in the sheet would likely compromise the shape of the hole, so I had to redesign some sections several times.
I was having the same problem with the graphics car supports and was unsure if they would still hold thier shape after being bent
I'd recommend this technique since 3D models can sometimes detach you from the relative size of objects.
An ITX motherboard and a SFX/short graphics card.
Side note: the questionable meatballs are NOT mine
I chose the Flex ATX form factor for its tiny height, just 40mm! The SFX power supplies were around 80mm and up. I started modelling and worked on translating my concept designs into a technical design
I decided the simplest layout of positioning the components next to each other would allow me to keep the case in a flat console style.
I explored a bunch of different front port options
Investigating ways that the Graphics car mounting would work in the simplest way
I started mapping the mounting holes for Flex ATX PSUs
The front panel assembly for the USB's + power button was something that I would have to create.
This was an early solution I came up with.
The tolerances were going to be tight. I learned that folding very near holes in the sheet would likely compromise the shape of the hole, so I had to redesign some sections several times.
I was having the same problem with the graphics car supports and was unsure if they would still hold thier shape after being bent
Last edited:
