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[Build Log] Freilite Brevis S - GTX 1070 and FlexATX in a <5L package - Page 6

post #51 of 86
Thread Starter 
A few updates!
1. Thermal Divider

So I've finally made up my mind about how the thermal divider should look and this is what I came up with:




As you can see, there are cutouts for the HDDs and the PEG connectors, but other than that, this 6mm thick piece of acrylic insulates the PSU from the GPU both thermally and in terms of airflow, so when a GPU is used that dumps most of its heat into the case, the PSU should stay as unaffected as possible and the heat will be exhausted through the side and back vents.

2. Back Vents

Because cards like that partially exhaust at the PSU and because there are a few Mainboards that block their side exhaust, I decided to add back vents to the case to allow the hot air to take a controlled path. The vents above the Mainboard and below the GPU are cut over the bend to prevent the sheet from ripping at those edges. When the time to prototype comes, I'll get different versions of those back panels to see whether the vents will actually make a difference.




On a side note, that picture also shows the new GPU mounting with screws and small cutouts for the bracket tabs to fit in.


4. Vent redesign

As you can also see in the previous picture, the vents for the top and front panel were redesigned to fit together better. I didn't find a vent pattern for the front panel that fit with the angled vents on the top panel satisfyingly, so I made them the same. These may still be changed but right now I'm quite happy with them. Maybe I'll get different versions for those parts as well and see which pattern looks best in reality. I could also learn to render properly, but that's not nearly as much fun.




5. Horizontal Stand

You may have noticed four odd holes in the top panel in the last picture. "What are those?", I hear you ask. Well, I'm glad you did because those are the mounting holes for the new Horizontal Stand:




This stand consists of a sheet of aluminium and a block of transparent acrylic which is screwed to the top panel from the inside. Then the top panel is screwed to the case, and then the stand is screwed to the block of acrylic.
This means that the installation is a bit complicated, but it also means that the stand is very sturdy, very stylish, and allows for optimal airflow. I reckon the stand will be sturdy enough to place a screen of virtually any size on the case. This design also allows the top panel to stay relatively unaffected optically.

6. VESA Mounting

And the four holes for the stand also allow for a VESA mounting solution. To make that work, I adapted the idea of french cleats in woodworking to sheet metal:




The grey piece get's screwed to the VESA75 mount, for example the back of a screen while the blue piece get's screwed to the top panel like the horizontal stand. Then, you just let the blue piece slide into the grey piece and secure them with two screws. Those pull the angled flanges together so they are secured quite easily. I may need to add ball-washers to account for bending, but the basic principle should work.


That's it, thanks for reading! biggrin.gif
post #52 of 86
How's this coming along? Have you entered the construction phase? I don't see myself finishing my Slim Machine any time soon so this is the closest thing I have to follow biggrin.gif
post #53 of 86
Thread Starter 
Quote:
Originally Posted by ccRicers View Post

How's this coming along? Have you entered the construction phase? I don't see myself finishing my Slim Machine any time soon so this is the closest thing I have to follow biggrin.gif

Unfortunately there was no progress made, I was on vacation for the last three weeks without my workhorse, and I recently upgraded to Windows 10 and still have to get everything back up and running again.

The only change at the moment is that I'll have to ditch front audio for now because it is just too much additional work, unless I find someone who really knows their way around electrical engineering that wants to do that part for me.

The design itself is pretty much finished right now, I need to either make a prototype out of wood or cardboard myself now and talk to possible manufacturers for the metal parts. Maybe I'll try to make a prototype out of aluminium myself, I have access to tools for cutting and you already showed that bending aluminium isn't that hard at all.

Thank you so much for sticking around! thumb.gif
Edited by iFreilicht - 8/27/15 at 4:34am
post #54 of 86
Thread Starter 
Not really an update, but I started working on the project again. If you aren't interested in technical stuff about the case, you can safely ignore this. wink.gif

Mostly clean-up work, restructuring of the cad model, but I also wanted to ensure that this case is going to last.
So instead of having tapped threads for all the screws, I will use self-clinching nuts, specifically Penns F4 Series. Very durable, very space efficient.
Using these nuts instead of deeper ones is required to comply with the ATX standard in terms of distance from the mainboards conducting components, and I think they look a lot nicer than protruding nuts.
This means that the main mounting panels now need to be 1.5mm thick instead of 1mm, but I don't see that as a disadvantage yet.

I also decided to scale the motherboard screws up from M3 to M4 to have more surface area available for the motherboard to rest on, both on the standoffs and the screwheads. I know this is a bit unconventional, but with M3, the standoffs are extremely narrow, and this case is supposed to be put in backpacks and take a bit of a beating, so I don't want to take any risks.

Two decisions are coming up that I'm a bit undecided about:

1. Should the currently blank "bottom panel" get intake vents for the PSU, just like the top panel has them? It would greatly increase the amount of airflow available to the PSU, especially when it has a lot of cabling to deal with. On the other hand, that could really hurt the aesthetics for some people, I kind of like having one completely plain panel.

2. Should the HDD mount be made thicker by 0.5mm as well? It doesn't really need to be that thick in terms of stability and it will give the HDDs less room to vibrate, but it would allow me to use ISO-standardised countersunk M2.5 screws, because their head is 1.5mm tall. There are screws that can be countersunk into 1mm thin sheets, but those are really hard to come by and that may hurt users that lose screws. I could also make the case another Millimetre taller to compensate for the additional height.
post #55 of 86
Good to see you're still developing this super-model-thin case.

#1 - Tough call. Agree with both points. If it were me, which thankfully it isn't, I'd increase the thickness with a vanity panel offset by 15mm that covered the vented panel. Good thing I'm not the designer.

#2 bothers me in this tiny form factor. Mechanical drives need to get their own room, er, case or NAS. If you can push the design phase out another couple years, the solution will be obvious. Intel/Micron are projecting 30TB SSDs for 2018 and 100TB SSDs for 2020. Again, if were me, and again it isn't, I'd make this a SSD-only refuge.

Look forward to the next design phase next year. And the one after that. smile.gif
post #56 of 86
Thread Starter 
I think I'll have to make two panels and see whether the additional venting is worth it or not. Yeah 15mm are absolutely unacceptable biggrin.gif

I'd rather have SSD storage only as well, but as of now, they are too expensive for a lot of people, including me, and I want to enable the use of a PC in this case as the main rig, so the option has to be there.
But yeah, HDDs aren't long for this world anymore.

Haha I hope I'll get at least the design phase finished this year biggrin.gif
post #57 of 86
Thread Starter 
I've finally got a chance to test the LiHeat A type riser today that they've sent to me a few weeks ago. Not anything to report really, everything worked just like I didn't use the riser, no matter how I bent or flexed it, and it will fit inside the case just how I planned it to. What a boring update.
post #58 of 86
Boring updates are the best kind of updates. After design breakthrough updates, fabrication updates, FLEXie PSU updates, sub-zero nano cooler updates, nano finish updates, nano paint drying updates, boring updates, no updates.

See! Right near the top. Thanks for the update! biggrin.gif
post #59 of 86
Are the volume saving not worth the trade off for SSD only? I imagine if you have space for 1-2 SSD using that space for an HDD is really not that big of a change.

I only made enough room for onboard M.2 so far; I haven't even looked at the difference while working on my build. I'm still debating adding a single SSD bay but it would increase the height at a 1:1 rate, so unless I need more airflow and have to put in a fan somewhere I don't think I will be adding a drive bay.
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CPUMotherboardGraphicsRAM
i7 4790 Asus Maximus VII Impact ASUS GeForce GTX 970 DurectCU Mini Corsair Vengeace LP 
Hard DriveCoolingOSMonitor
Kingston HyperX Predator M.2 2280 PCIe SSD Cooler Master Sickleflow 120 Red LED Windows 10 Inside Build 10576 Benq XL2411Z 
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Asus Mb169b+ Asus Mb168b+ HHKB PFU 2 FSP500-50FSPT 
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post #60 of 86
Thread Starter 
Quote:
Originally Posted by Teebs View Post

Are the volume saving not worth the trade off for SSD only? I imagine if you have space for 1-2 SSD using that space for an HDD is really not that big of a change.

I only made enough room for onboard M.2 so far; I haven't even looked at the difference while working on my build. I'm still debating adding a single SSD bay but it would increase the height at a 1:1 rate, so unless I need more airflow and have to put in a fan somewhere I don't think I will be adding a drive bay.

No, not in my eyes. SSDs are fast, small and, well, solid, but they are too expensive for me so I still need HDDs. This case will house my main rig which is used for Programming, Modelling, Gaming and other stuff, so I want to have a lot of storage space for the least possible price, and that means HDDs all the way.

SSDs are a bit less susceptible to thermal stress as well, most HDDs have a maximum operating temperature of 60°C while SSDs commonly have 70°C, so while you could put SSDs below a GPU and be probably fine, HDDs are not fit for that environment at all.

And additionally, I could only go down by a few millimetres because else there'd be no space for the I/O shield to fit.

There is a certain point where decreasing size is not worth the tradeoffs anymore, NotFromConcentrate painfully learned that with the S3 Mini. It was a great case, but it was so slim that you had to lasercut a custom I/O shield for your mainboard. No fun.

In the future, this might change, but I won't design a case for technology that's viable in a few years, I can still do a revision then.
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