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Laser Cut Mini-ITX Case From Scratch

Laser Cut Mini-ITX Case From Scratch
This Instructable is designed to show you how to make your own Laser cut Mini-ITX computer case.

This is also for the fourth Epilog challenge, so if you like it, then please vote!

There is a nice low cost service that can cut this computer case for you called ponoko.com and we use them regularly for doing custom computer cases.

Computer case will be:
Screwless, minus mounting of the 2.5" hard drive, Slimline DVD/BR drive, and an externally powered Mini ITX Motherboard
Laser cut power button
Two front mounted USB connections
All parts small enough to fit on the Epilog Zing's table
Optimized to reduce plastic waste
Made of Acrylic
Micro-Tower
Fanless, Cooled by convection
No commercial use of this design or any derivative work unless you previously license it from me.
 
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Step 1Holes Holes Everywhere...

Holes Holes Everywhere...
First thing is to find where all of these lovely holes go... and realize that I'm not the best sketcher in the world (give me time and I can do works of art... this is a sketch... gotta get it down on paper somehow)

You've got:
Holes on the back for the motherboard, power supply input, Expansion Card
Holes on the front for the power button, LED, USB, and DVD Drive
Holes on the backplane for the Motherboard Mounting, and expansion card
Holes for Mounting the Hard Drive
Holes for Mounting the DVD drive

There are also clearance issues to account for, every motherboard form factor has lots of mechanical specifications. Luckily there's a website for this: http://www.formfactors.org/ . They will have every measurement you will need to make your own case from scratch, if you don't have access to the internet (for whatever reason) you can also measure your parts with a micrometer.

Where to go from here:
I always start with the design, and look of the case first, then work on the motherboard dimensions and mounting points since it's the largest part, then to the hard drive and dvd.

I'm going to be making this as a fairly standard form factor case, motherboard vertical, cdrom and hard drive up top, mini tower look.

The Motherboard is very small in comparison to an ATX or uATX form factor, it's only 170mm x 170mm, or about 7"x7" and was created by Via in Taiwan. I won seventh place in an international design competition way back in 2001 by via arena using this motherboard, so it's still has a soft spot in my heart. The mounting points used from the ATX specification are C,F,H, and J, I use about a 1/4" standoff in this design (see the next page...)

I will be using a Slimline DVD drive, and 2.5" hard drive (you can even use a SSD if you want)

I'm lucky to have designed hundreds of computer cases, so you will probably have to read a little between the lines, and figure a few things out, but if you comment on the page you have an issue with, I will make sure to improve the instructable for future people.

Start with the design
I start with the base, make sure there are points where air can flow, I make an accounting for a flat bottom with vent holes in it. I also try to make the base integrate with the sides of the computer case, giving it a nice top to bottom flow... a very eastern look... to save time since I am trying to make the deadline, I'm just going to use some simple shapes, nothing fancy, and there will be some screws visible on the side where the motherboard is, but I can make an adjustment to the design as I've accounted for extra material needed for a nice cover. The cables will come out the back as expected in most tower configurations.

I have included the specifications for both ATX and Mini-ITX so you can have the precise measurements.
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4 comments
Nov 2, 2011. 1:50 PMplayful-geometer says:
I thought this was a pretty nifty entry for the contest so I voted for it. I've found there are so few entries that actually exhibit creativity using a laser cutter so kudos for putting together something relevant. You can see my entry here if you like:Quasicrystal Star Lantern
Oct 31, 2011. 10:32 AMzazenergy says:
very thorough! do you have some photos of the final product you could share?

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