Tag Archives: Projects

Frosty, the 3D printed Mini-ITX case

I made another computer case.

Frosty - fully assembled case
Frosty – fully assembled case

Our home server/HTPC broke down after close to 6 years, and it was time to replace it. Being me, I didn’t want to just buy an off-the shelf machine – where’s the charm in that?

This one is a little different than my previous builds. I didn’t modify an existing enclosures this time, but instead created one completely from scratch. 3D modeled and 3D printed based on nothing more than my own ideas and my own measurements.

I do like reusing and repurposing existing things, and I try to not get stuck in a throw-away mentality. This new case is however entirely made from renewable or recycled materials. The main body is printed using biodegradable PLA plastic (made from corn starch or cane sugar). The only other parts of the case consist of a power switch and an LED, both taken from the failing computer it was meant to replace.

I had an idea of a completely smooth case without any visible corners, with a single air inlet on the top connected to the CPU fan. A number of smaller air outlets near the bottom would force the airflow to spread out around the motherboard and the rest of the components. The shape would initially resemble a simplified cloud, but that quickly changed.

I was impressed with the layout, performance and tweakability of the Asus H81T Mini-ITX motherboard that I used for the 1-Up NES case mod, and decided to use another one for the new case. Most important was the fact that the H81 has a rear power jack that fits standard laptop power bricks, and I could pick up a used one from Dell on eBay that worked right away, no modifications needed.

I used a modeling tool that I already knew; Tinkercad – a free, browser-based online CAD tool from AutoDesk. It has limited functionality and performance, and I’m planning on learning a “real” CAD program soon (Fusion 360?), but I was eager to get started right away. After a number of versions and revisions, I had a rough printed version (5) up and running 24/7 for about a month. After a lot of checks, changes and tweaks, I finally printed the final version (8) on my heavily modified RigidBot 3D printer. By now the initial project name Fluffy had changed to Frosty, and the design would now look more like snow than a cloud. I made a snowflake design for the air inlet, which also serves as a fan guard.

After sanding I applied a few layers of acrylic clear coating to get more of a snow crust look. PLA is notoriously hard to sand as it melts and clumps up if you go too fast due to the friction. I only went up to 240 grit, which is why the surface isn’t perfect. If this was a job for someone else I would go to at least 800 grit, but as it will only be used at home this is good enough.

Bottom and top parts after sanding and clear coating
Bottom and top parts after sanding and clear coating
Insides before assembly
Insides before assembly

When assembling the computer, pretty much everything fit perfectly. I only had to drill the hole for the LED a tiny bin larger and use a scalpel to shave off about 0.2mm for the power switch.
Unless you have your ear right next to the computer, you can’t hear it running. Since I use an SSD, the only moving part in the computer is the CPU fan, and Intel did a fantastic job with making it whisper quiet – at least when enabling the Q-Fan control in the UEFI bios.
With the CPU on full load on all cores at 3.2Ghz, the computer is still almost dead silent and the CPU temperature is usually around 30°C.

All in all, I’m happy with the results. I’ve learned a lot and had fun doing so.

If you want to print your own, I’ve made the .stl files freely available at http://www.thingiverse.com/thing:1241259

Outline of case functionality
Outline of case functionality
Power LED inserted
Power LED inserted
Power switch inserted
Power switch inserted
Empty case, seen from rear
Empty case, seen from rear
Fully assembled case, seen from rear
Fully assembled case, seen from rear
Everything in place except top cover
Everything in place except top cover
Everything in place including top cover
Everything in place including top cover
At it's current home, next to external HDD. Previous computer occupied entire shelf, hence the extra space.
At it’s current home, next to external HDD. Previous computer occupied entire shelf, hence the extra space.

The Chest Case Mod Project – Part I

Last week I ordered a bunch of components for building a new computer. The main reason is that I want to be able to use triple screens with Eyefinity, and my current setup can’t handle that. I’ve been using dual monitors for about 7 years and never looked back, but I would like some more screen estate, especially when working in Photoshop and the likes, and playing 3D games. Games like Dragon Age (I/II) etc works fine with dual screens, but I find it annoying that all texts etc are split in the middle between two screens. For better vertical resolution, I will use my three 21″ Dell screens with IPS panels with extreme viewing angles and a lot better color depth than “normal” computer screens. And they can pivot, meaning I can place them vertically. The full resolution will be 3150×1680 with an aspect ratio of 15:8, slightly wider than standard 16:9 widescreen. And since my current computer is 5 years old, I thought it was about time to buy a new rig anyway.

The thing I enjoy most about getting a new computer is to build the case. To be able to fit the 3-slot wide, passively cooled graphics card alongside the CPU cooler, I could not go with a 17x17cm Mini-ITX motheboard this time as I have for my last two builds, but had to step up a level to a 24x24cm Micro-ATX instead. The size for the components are perfect for a case that I will build out of a small wooden chest. I will try to make the  chest to look as close to the  original as possible, not revealing that it actually contains a computer until you get a closer look at the sides and the rear.

Since everything but the CPU is passively cooled, even the PSU, the case will require some airflow as to not overheat. I will go for a silent 12cm fan on each side with adjustable speed that you can turn up if needed while playing heavy games or during a hot summer (Or I can just open the chest lid). The big problem will be to have air vents in the chest without it looking too strange. Right now I’m in the decision process on whether I will cut a 12x12cm hole on each side and place a fan grill above them, or if I will simply cut a lot of smaller holes in the chest around where the fan will be placed on the inside.

Two days ago I downloaded Google SketchUp, a free 3D modeling program, to do a design draft and make sure all components will fit. It was quite easy to learn, and after about a total of 8 hours learning and designing, I’ve come up with this. All done from scratch:

The Chest Case Mod - First 3D draft

The lid in the model is semi transparent in order to actually see the parts inside the chest. Everything is made with millimeter precision, and I’ve used my slide caliper plenty to measure everything correctly. To be less then modest, I’m quite impressed with the progress I’ve made in this short time. I do have previous 3D modeling experience, but that was back in 1995-96 in Autodesk 3D Studio for DOS. I can tell you this: SketchUp is a lot easier to learn.

The computer components are all top notch, and it’s hard to get better components than these without a major step up in price:

  • CPU: Intel Core i7-2600K (stock cooler to start with, might upgrade later)
  • Motherboard: ASUS Maximus IV GENE-Z
  • Graphics card: PowerColor Radeon HD 6850 1GB GDDR5 SCS3
  • PSU: Seasonic X-460FL
  • SSD: Corsair SSD Force Series™ F115 (115GB, system disk)
  • HDD (x2): WD Caviar Green WD20EARX (2TB, storage disk, will use RAID 1)
  • RAM: A-Data DDR3-1600G (8GB)
  • Case fan (x2):  Scythe Slip Stream PWM 120mm Adjustable
I expect most parts to arrive tomorrow, and hope to get started with the build soon.

Unexpected consequences

Have you ever thought about how the meeting of two people affects the world around them?

Consider a man and a woman in their thirties who know nothing about each other, walking in opposite directions towards one another in the middle of the city. Let’s call them Derek and Susan. Suddenly Derek trips on a crack in the pavement, and falls over just in front of Susan. She stops to help him up, they smile, and after an awkward moment of silence she asks him out for a cup of coffee. Ten minutes later they sit in a café, she’s having a latte and he’s having espresso. When they leave, Derek asks for her phone number. She jots it down on a note, and gives him a peck on the cheek. He says he will call her, but he never does.

So how has this short meeting affected the surroundings?

First off, the stumbling in the street:
Unaware to Susan, Jake, a pickpocket were just about to snatch her wallet from her unintentionally open purse when she suddenly stops to help Derek up. When bending down, Susan’s purse slides down her shoulder and out of reach for Jake, who has to leave empty-handed. A blessing in disguise for the tired pickpocket, who otherwise would get caught using Susan’s credit card, starting a downward spiral that would ultimately lead to his demise.

Second, on the way to the café:
Short on cash, Susan stops by a cash dispenser. Derek offers to pay for her coffee, but she declines with a wry smile. Jonathan, a young film student next in line gets inspired by this scene, writes a blockbuster and dies four years later from an overdose of heroin, blinded by his own success.

Third, at the café door:
At the door they bump in to Betty, an old classmate of Susan. Betty is in a hurry, but since they haven’t seen each other in fifteen years, they chat for about two minutes before she rushes off. That is enough for her to miss her bus, having to wait for another 20 minutes. At the bus stop she meets Kevin, another classmate from the same class as Betty. They sit next to each other on the bus, laughing and remembering the old times. At his stop he asks her to come by his place. Having forgotten why she was in a hurry in the first place, she blushingly says that she’d like that. A year later, they have a baby girl named Fiona.

Fourth, at the café:
Jenny, an exchange student from who works part-time at the café, takes their order. When preparing Derek’s espresso, she accidentally puts her hand on a hot part of the espresso maker, scalding two of her fingers. Studying music and playing the violin, she won’t be able to perform on the next school concert. If she would have played at the concert, a talent scout would have discovered her, and she would release two mediocre albums in her music career. Instead, she works full-time at the café after graduating.

Fifth, when leaving the café:
Outside the café sits Elton, a homeless man. He asks the couple for change. Thinking he will only use it for drugs or booze, both Derek and Susan ignore him. Elton freezes to death the very same night, not being able to afford shelter.

Sixth, when Derek gets home:
When Derek gets home, his wife Kate is already there. She usually gets home about two hours later than Derek, and is used to having Derek meet her at the doorstep every day. She is just about to ask him where he has been when she sees the slight lipstick mark on his cheek. Instead of asking him about it, she doesn’t say a word the rest of the evening. Later that night when Derek has fallen asleep, she cuts off his penis with a kitchen knife, Lorena Bobbitt-style. In the aftermath, she doesn’t believe Derek when saying him and Susan only had a coffee, so she tells him she wants a divorce, moves to another town and lives a miserable life. The doctor’s not being able to re-attach his penis, so does Derek.

Seventh, at Susan’s place:
A week after they’ve met, Derek still hasn’t called Susan. This is of course because Derek is in the hospital with a chopped off penis. But Susan doesn’t know that, and simply thinks that he has ditched her. This frustrates her, and she unconsciously takes it out on her work as a business negotiator for a software company. This proves however to be a successful method, and she takes the company to new heights using her anger at men in general as a mental negotiation method. She writes a book about it, gets rich from it, and lives out the rest of her days with a mute Japanese named Takeshi. “If they can’t speak, they can’t lie”, she humorously says to her friends.

So what can we learn from this short story about two people having coffee together? That everything we do affect other people. It sets in effect events too small for us to notice, but events start other events which in the end might change the world as we see it.

That’s something to think about the next time you have a cup of coffee with someone.

———-

The above was written as part of a school project I did some years ago.  Discussing chaos theory with M yesterday, I came to think of it and thought I should post it.

Analog week

Greetings, humans!

Merry Christmas, Happy New Year and all that. Hope the holidays have treated you well.

Personally, I’ve been spending to much time in front of the computer and the screen and have decided to take a break.

Starting to day, I will not sit in front of the computer, watch any movies or playing any video games (including RISK on my cell phone) while at home. Right now I’m at work where I have to use the computer, so I justify some minor blogging and facebooking from there with that.

I will try to catch up on my reading and possibly some project that has been laying around (Got a brand new wireless Dremel for Christmas!), but the main reason is to simply disconnect for a while.

Let’s see how long it takes before I forget myself – I hope I can last a week anyway. 😉

Update:

I lasted the whole week and finished reading two books. Although on Sunday evening I watched a movie because I was utterly bored. 😉