PC Case
Design Goals & Restrictions
Must fit in FAA permitted carry-on suitcase
Must be made in under a week
Must fit all components of current case with the exception of hard drive
Durable enough to withstand drops in suitcase
Aesthetically pleasing to sit on desk
Notable Design Decisions
Prints in 4 pieces and uses interconnecting brackets to allow for printing on my printer while still remaining strong and achieve aesthetic goal
Minimizes non 3D printed parts to just those needed for aesthetics and one structural backbone panel
Placement of components such as fans are placed over the seam lines to use the component to reinforce the weak point for zero material or manufacturing cost.
Unconventional placement of power supply using right angle connector to minimize Z dimension
Mistakes and Improvements
I accidentally made 3 sets of connecting bracket holes M3 clearance instead of tap and didn't notice until the first part was made.
One location needed a connecting bracket to keep the seam hidden but is currently lacking
Inset on the front was originally designed for a piece of brass I had laying around but I made it too shallow and the removal of it will improve the 3D prints while keeping aesthetics similar by using vinyl wrap instead.
Design for Manufacturing of 3D Prints
I have a personal hatred for supports on 3D prints and will go to great lengths to avoid them when possible. Often times people will not think about the tiny modifications they can complete to make a part much easier, faster or cheaper.
This case had many examples like this two pictures where a simple chamfer on the right can prevent the need of supports that otherwise would be needed for the part on the left.
