Prototype Sputnik - a 7.5L HTPC

Shatrod

Cable-Tie Ninja
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Redshift Project
Gold Supporter
Dec 6, 2019
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Hi Everyone.

I have been away for a bit but figured its time i come back and share what has been occupying my free time as of late. I have been designing a simple 7.5L HTPC case with a focus on storage. My design goals were simple: don't use any risers or extensions, design around standard sff parts (sfx psu mostly), support a few drives, have some front IO, and look good in a living room :)

I feel like I mostly have what I set out to make. The sheet metal design is almost done, just needs to be triple checked and I will start looking at manufacturers near me to prototype with.
I already designed and prototyped the front IO PCB. The case sports two usb3.0 ports running full usb 3.0 speeds, and a cherry switch for power button.
For storage you can fit four 2.5" drives. Max GPU length is 204mm with 2.25 ish slot thickness. Although an SFX-L psu will fit, the vents are only designed to accommodate an SFX.
The cpu cooler is limited to 65mm tall, but really that will choke the fan. Practically I can only see this working with around 45mm tall coolers.
To help with cooling a 120mm fan can be mounted in the front.

Without further delay, some renders and pictures. Let me know what you think!
Update march 2024: first prototype is made!

Update August 2024:
I decided I want to try to do this for real and try to bring it up as a low volume product. To that extent I had to put the project on a small hold while I started building up supporting infrastructure. I opened a sole proprietorship in my province and built a website to host my current and future work. You can check it out below, as well my Instagram redshift.project. I also added hardware compatibility graphcis to this post.


For the case itself, i did notice some minor tweaks need to be made. Some of the screw holes don't line up perfectly (though they are so close i didn't notice until i was auditing the cad model, the actual prototype it was not evident at all). Im also battling with some tolerance issues with the wood. I need to make a bunch of prototypes tweaking the wood slightly until its a good fit every time. I also chose not to 3d prin the button but isntead go for an off the shelf keycap. I also need to see how to best tweak the front IO PCB. It works but, it could be better/easier to make. I will also be finishing the last 3 prototypes.















 
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Shatrod

Cable-Tie Ninja
Original poster
Redshift Project
Gold Supporter
Dec 6, 2019
210
374
Small update. I have been talking to a few manufacturers and am zeroing in on a local one that is reasonably priced. I do have to update the design for manufacturing. Mainly, the front vents need to change from the concentric wedges to the same slots as the top. I also extended the same methodology for the back. All in all, i am happy with the updated look, i don't think it detracts from the theme at all.

 

Shatrod

Cable-Tie Ninja
Original poster
Redshift Project
Gold Supporter
Dec 6, 2019
210
374
Hi all.

It's been a few months but I'm excited to share a big little update. I got the first prototypes made!


Still need to powder coat, assemble, make the wood front, get screws and other trimmings but we're getting there! Hopefully fitment test and first build soon.
 

Shatrod

Cable-Tie Ninja
Original poster
Redshift Project
Gold Supporter
Dec 6, 2019
210
374
Big update, the first prototype is fully made.
I CNCed the wood front, sourced all the screws (they are very flush). The whole case came together perfectly. I will also be editing the first post to reflect that this not just a render anymore :) First build coming soon to test hardware fitment. Here are some pics:









As well as some in progress photos of making the wooden front:
 
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ASAP

Minimal Tinkerer
New User
Mar 10, 2024
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This is an intriguing layout. How well does the GPU cooling work with the card upside down? Is there room for a radiator and fan on the front to be used in conjunction with a pump/res waterblock combo?

Great job, it looks awesome!
 

Shatrod

Cable-Tie Ninja
Original poster
Redshift Project
Gold Supporter
Dec 6, 2019
210
374
This is an intriguing layout. How well does the GPU cooling work with the card upside down? Is there room for a radiator and fan on the front to be used in conjunction with a pump/res waterblock combo?

Great job, it looks awesome!
Thanks!

I haven't done extensive testing just yet, but if my understating is right the GPU cooling should work fine in this orientation. As far as vapor chamber/heat pipes are concerned it's the same as the usual way. And convection really shouldn't play that much of a role if you have fans going. The vents wrap around the sides specifically to let GPUs exhaust out the sides if your fin stack points sideways.

There is definitely no room for a radiator. Motherboard to front panel clearance is 30mm. Works out to be just enough for a standard fan and the 24pin cable clip.

I think the length width and height ratios make the case appear bigger than it really is.
 

Shatrod

Cable-Tie Ninja
Original poster
Redshift Project
Gold Supporter
Dec 6, 2019
210
374
Update August 2024 (also updated first post):
I decided I want to try to do this for real and try to bring it up as a low volume product. To that extent I had to put the project on a small hold while I started building up supporting infrastructure. I opened a sole proprietorship in my province and built a website to host my current and future work. You can check it out below, as well my Instagram redshift.project


I also made some GPU display stands, which are available for purchase now. I am hoping to use that product to build up a bit of a brand and to subsidize the case development as its becoming a little difficult to prototype things out of pocket. I am now getting back to the case itself and trying to put in the last 10% of the effort to polish everything off. Here is a list of TODOs:

1) clean up the CAD model. I noticed while auditing it that some screw holes don't perfectly line up but its so close that i didn't notice on the real thing while building the prototype.
2) tweak the design of the wood front. It will visually stay the same, but I need to work in better tolerance control. When this becomes a small volume thing I don't want to be hand sanding every single piece for fitment. Also depending on the choice of keycap, the square cutout can be too tight and the keycap can get stuck. I also need to address that.
3) keycap itself. 3d printing it has proven to be not great, and they're not expensive, so il probably use an off the shelf keycap. X D A profile.
4) the SSD bracket needs a bit of tweaks. I am a little concerned about SSDs touching the gpu back plate and shorting things if there is no back plate... so i think il extend the plastic there to act as a bit of a shield for isolation. On the flip side, the plastic then touches the back plate which could get quite hot? Or not really given the size constraints. Basically this needs testing, but i dont want to start shipping cases until I can get a chance to test it. I need to get my hands on the gigabyte 4070 dual fan that (maybe) fits in this case as its the hottest card i can think of to test this with.
5) tweak the IO PCB. Specifically the low profile usb internal cable is a pretty hard item to find. I need to find one that only has the connector on one side so i can solder it directly to the PCB. This makes it even lower profile and eliminates some connectors. I also want to look into pcb assembly services. I can see myself soldering on a few usb ports for prototyping but not hundreds for production.
6) (optional) thermal and noise testing. I think it not required but would be nice to make a "representative" build to push this case to the limit and do some temperature and noise testing. Is this something you would like to see? What would in your opinion be good hardware to use?
 
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