Introduction
This project is meant to be a personal one. I have never designed a case before, so I do start from zero, literally. The general goal is the learning experience (tech and designing wise) as well as the finished build in the end. I am not using any fancy tools/programs, keeping it simple and cheap. The idea is, to create a portable case that can support hardware which is more powerful than a typical APU build. The max total system power draw should be around 200w, so the case is going to be designed for short GPUs (mostly single fan) and ITX boards with low profile CPU cooling solutions. Regarding the execution, it should be kind of an "ikea-style" approach. Just as Lazer3Ds concept of shipping all sheets and mounting hardware in a box for customer assembly. In my case, it's meant to be assembled just once. Getting the pieces made from clear acrylic gives me the freedom to personalize the case as I want to in the end (painting, vinyl wrapping, you name it).
I started my first drawings, using Inkscape in summer of 2019. I probably had a million different approaches until I settled with a general idea. It consumed a lot of evenings but I learned a lot in that time too. The order of the (first?) prototype was placed in early December 2019. I was sick just sitting in front of the screen. I had to get some sort of prototype to check all my spacings and if 3mm sheets would create a stable chassis. That's where I am today and where this thread will continue from.
Specifications (updated July 5, 2020)
The build (finished on August 23, 2020):
After I ordered all parts and the vinyl wrapping, I started to assemble the case by removing the protective plastic and screwing in the motherboard standoffs. I had to dremel the mounting holes a bit wider to fit the standoffs properly. I did this on purpose.
After all standoffs were screwed into the motherboard tray, I put all panels together and started glueing everything bit by bit. I used a glue that contained a solvent, so it "melts" the surfaces of the acrylic sheets and bonds everything permanently together (like welding).
The case got 24 hours time to cure completely. The next step was applying the vinyl wrap. That took a lot of time and patience. I got it done eventually. I did quite some mistakes regarding the corners but everything could get fixed. The finished work is pretty neat.
Since the case has been assembled, I was able to start building the actual PC. I used a Gigabyte B360N Wfi Mainboard with an i5-8400, two 8GB modules of HyperX Predator 2666MHz CL13 RAM (heat sinks removed, otherwise it couldnt fit into the case) and a Noctua NH-L9i Chromax CPU-cooler. The GPU is MSI GtX 1650 Super Aero ITX 4GB that got connected to the mother board the a Linkup PCI-E riser cable (30cm + shielded). Storage wise, I used a Crucial MX500 M.2 SSD (500GB).
The CPU compartment was quite a tight fit. There is maybe just 1mm of space between the cooler and the side panel. I calculated it differently (with more space) but it does fit after all.
The assembly was quite easy for such a small case (if you use your brain before you do stuff ). You see the I/O shield installed in the pictures (for the "whole" picture) but I actually left it out.
After the mainboard was comletely mounted, I went for the GPU. Sadly, a couple of mm were missing at the slit where the GPU braket slides into. So I had to mount the I/O shield first and attach the GPU back to it afterwards. It still fits nicely.
Unfortunately, starting up the PC gave me some trouble. Never booted into my drive but into the BIOS constantly instead. It took me couple of hours to resolve that issue. But after that, the PC is running fine with good temperatures. The wiring of the power button was a bit fiddly because there was no schematic for it.
I really like that random brushed look with the only led being the one of the power button. All fotos were made with HDR mode. The finish of the vinyl wrap looks like it has some sort of a mirrrow effect. It does not have that! I think thats the result of the HDR image processing. The case looks much more "matt" or "muted".
The resume:
Well, what a wild ride for my very first case. It took me a long time and it isnt perfect sill. The CPU cutout of the side panel is not centered with the CPU fan and the fan makes some noise when it ramps up (due to the turbulances it creates because it is too close to the side panel). This is something I would change in the future (even considering a 100% cutout with no restrictions what so ever). Overall, the PC is VERY! quiet when there is not a massive load.
The silent performance was the main reason why I want to go with an external power supply. Seeing all the videos on similar cases, using Flex-ATX power supplies, made me cringe. I had one from Silverstone myself and I couldnt stand even the noise under idle load! Now, this is much better! External PSUs have their advantage in this regard.
GPU wise, the "mounting slit" need to be a touch wider, so the GPU can be installed without taking apart. No additional noise coming from there, since the clearance the the side panel is fine.
The side panels really could have been 2mm instead 3mm. They dont contribute to the structural integrity of the case. As I tested the strength of 2mm sheets (190x190mm), they dont bend much. If I would have gotten 2mm panels, I could have added more clearance for the CPU fan. Everything else need to be 3mm or above! The case is very sturdy. I handled it with all gear inside multiple times today (even a bit more aggressive) and it did not flex or break. It is really like a tank. I have added 10mm clear glue-on feet to give it some room for fresh air vom below.
The total cost for the final case (without the vinyl wrap, which was my personal choise of giving the case its individual appearance) was around 70-75 Euro. Thats everything bought as a consumer with shipping, taxes etc. No bulk discounts or stuff like that. It includes the laser cut acrylic panels (+ shipping), the power button and all small parts like skrews and mounting blocks (+ shipping) as well was the glue-on feet. To be fare, I selvaged the power button cables from another "dead" case but those are cents really.
This total project cost, adding the prototype and couple of smaller purchases is around 120 Euro. Very low, if you ask me! And btw, no cost for programs etc. All freeware!
I am really happy with the result and cant wait to make a next version with more improvements
The future:
Since there is room for improvement, I might go for a v2. Not sure if I really try to get this made out of aluminium. Maybe I could try to get a version done, which you can assemble without clueing (just mounting blocks). It will be over 4L though. I have now some time to think about those questions.
Just out of curiosity, is there actually a demand for such a case (even when its made out of acrylic?). Would it be better to use only mounting blocks or would be glueing ok, if the solvent is part of the shipment? The original reason to use clear acrylic was, that I have a "blank canvas" to paint or wrap it was I want to. I can change it in the future too, if the vinyl wrap gets old.
What I still have to deal with is the power solution. The pico 160xt with the adaptec 192w/12v power brick is giving me some trouble. But this wont be part of this thread anymore.
Anyway... thanks to everyone who followed this project and gave me some input
This project is meant to be a personal one. I have never designed a case before, so I do start from zero, literally. The general goal is the learning experience (tech and designing wise) as well as the finished build in the end. I am not using any fancy tools/programs, keeping it simple and cheap. The idea is, to create a portable case that can support hardware which is more powerful than a typical APU build. The max total system power draw should be around 200w, so the case is going to be designed for short GPUs (mostly single fan) and ITX boards with low profile CPU cooling solutions. Regarding the execution, it should be kind of an "ikea-style" approach. Just as Lazer3Ds concept of shipping all sheets and mounting hardware in a box for customer assembly. In my case, it's meant to be assembled just once. Getting the pieces made from clear acrylic gives me the freedom to personalize the case as I want to in the end (painting, vinyl wrapping, you name it).
I started my first drawings, using Inkscape in summer of 2019. I probably had a million different approaches until I settled with a general idea. It consumed a lot of evenings but I learned a lot in that time too. The order of the (first?) prototype was placed in early December 2019. I was sick just sitting in front of the screen. I had to get some sort of prototype to check all my spacings and if 3mm sheets would create a stable chassis. That's where I am today and where this thread will continue from.
Specifications (updated July 5, 2020)
- Dimensions: 190 x 190 x 110 mm
- Volume: 3.971L
- Materials: 3mm acrylic; 7+4 mm brass standoffs
- Design: sandwich design
- Max. GPU length: 180 mm
- Max. CPU cooler height: 38 mm
- Storage: M.2 only
- PSU: DC-ATX + AC-DC (dual PSU ready) - only 4pin din connector like pico/adaptec
The build (finished on August 23, 2020):
After I ordered all parts and the vinyl wrapping, I started to assemble the case by removing the protective plastic and screwing in the motherboard standoffs. I had to dremel the mounting holes a bit wider to fit the standoffs properly. I did this on purpose.
After all standoffs were screwed into the motherboard tray, I put all panels together and started glueing everything bit by bit. I used a glue that contained a solvent, so it "melts" the surfaces of the acrylic sheets and bonds everything permanently together (like welding).
The case got 24 hours time to cure completely. The next step was applying the vinyl wrap. That took a lot of time and patience. I got it done eventually. I did quite some mistakes regarding the corners but everything could get fixed. The finished work is pretty neat.
Since the case has been assembled, I was able to start building the actual PC. I used a Gigabyte B360N Wfi Mainboard with an i5-8400, two 8GB modules of HyperX Predator 2666MHz CL13 RAM (heat sinks removed, otherwise it couldnt fit into the case) and a Noctua NH-L9i Chromax CPU-cooler. The GPU is MSI GtX 1650 Super Aero ITX 4GB that got connected to the mother board the a Linkup PCI-E riser cable (30cm + shielded). Storage wise, I used a Crucial MX500 M.2 SSD (500GB).
The CPU compartment was quite a tight fit. There is maybe just 1mm of space between the cooler and the side panel. I calculated it differently (with more space) but it does fit after all.
The assembly was quite easy for such a small case (if you use your brain before you do stuff ). You see the I/O shield installed in the pictures (for the "whole" picture) but I actually left it out.
After the mainboard was comletely mounted, I went for the GPU. Sadly, a couple of mm were missing at the slit where the GPU braket slides into. So I had to mount the I/O shield first and attach the GPU back to it afterwards. It still fits nicely.
Unfortunately, starting up the PC gave me some trouble. Never booted into my drive but into the BIOS constantly instead. It took me couple of hours to resolve that issue. But after that, the PC is running fine with good temperatures. The wiring of the power button was a bit fiddly because there was no schematic for it.
I really like that random brushed look with the only led being the one of the power button. All fotos were made with HDR mode. The finish of the vinyl wrap looks like it has some sort of a mirrrow effect. It does not have that! I think thats the result of the HDR image processing. The case looks much more "matt" or "muted".
The resume:
Well, what a wild ride for my very first case. It took me a long time and it isnt perfect sill. The CPU cutout of the side panel is not centered with the CPU fan and the fan makes some noise when it ramps up (due to the turbulances it creates because it is too close to the side panel). This is something I would change in the future (even considering a 100% cutout with no restrictions what so ever). Overall, the PC is VERY! quiet when there is not a massive load.
The silent performance was the main reason why I want to go with an external power supply. Seeing all the videos on similar cases, using Flex-ATX power supplies, made me cringe. I had one from Silverstone myself and I couldnt stand even the noise under idle load! Now, this is much better! External PSUs have their advantage in this regard.
GPU wise, the "mounting slit" need to be a touch wider, so the GPU can be installed without taking apart. No additional noise coming from there, since the clearance the the side panel is fine.
The side panels really could have been 2mm instead 3mm. They dont contribute to the structural integrity of the case. As I tested the strength of 2mm sheets (190x190mm), they dont bend much. If I would have gotten 2mm panels, I could have added more clearance for the CPU fan. Everything else need to be 3mm or above! The case is very sturdy. I handled it with all gear inside multiple times today (even a bit more aggressive) and it did not flex or break. It is really like a tank. I have added 10mm clear glue-on feet to give it some room for fresh air vom below.
The total cost for the final case (without the vinyl wrap, which was my personal choise of giving the case its individual appearance) was around 70-75 Euro. Thats everything bought as a consumer with shipping, taxes etc. No bulk discounts or stuff like that. It includes the laser cut acrylic panels (+ shipping), the power button and all small parts like skrews and mounting blocks (+ shipping) as well was the glue-on feet. To be fare, I selvaged the power button cables from another "dead" case but those are cents really.
This total project cost, adding the prototype and couple of smaller purchases is around 120 Euro. Very low, if you ask me! And btw, no cost for programs etc. All freeware!
I am really happy with the result and cant wait to make a next version with more improvements
The future:
Since there is room for improvement, I might go for a v2. Not sure if I really try to get this made out of aluminium. Maybe I could try to get a version done, which you can assemble without clueing (just mounting blocks). It will be over 4L though. I have now some time to think about those questions.
Just out of curiosity, is there actually a demand for such a case (even when its made out of acrylic?). Would it be better to use only mounting blocks or would be glueing ok, if the solvent is part of the shipment? The original reason to use clear acrylic was, that I have a "blank canvas" to paint or wrap it was I want to. I can change it in the future too, if the vinyl wrap gets old.
What I still have to deal with is the power solution. The pico 160xt with the adaptec 192w/12v power brick is giving me some trouble. But this wont be part of this thread anymore.
Anyway... thanks to everyone who followed this project and gave me some input
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