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[scratch build] PROJECT SOPHIA - laser cut mdf case WIP

25K views 24 replies 7 participants last post by  owliwar  
#1 ·


UPDATE:
Project sophia is almost done, and i made a blog about it
http://projectsophia.tk/en/
check it here
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thanks

Current state of project Sophia:

Hello, I'm a product designer student in brazil and i was strugling to find a case that I'd like and could afford (because prices are kinda crazy here now) and so i begun to study about case building and scratch builds.


This project has been going for half an year now and i'm really close to completion. Since i had not the time or the money to have it cut before, I have only a bunch of beautifull renders. I have a working prototype but there is still upgrades to come. slowly, of course there are pics on the posts below


disclaimer: I have not received any money from any company (but I'd love to) and the hardware parts rendered in these images were available for free on grabcad.com and picked for best aesthetics

What happend: My laptop died and I needed another pc. i got some spare parts and brought my system but i hadn't all the money for the full system and so I was left with an really ugly case that still bothers me but i learned to apreciate the fact im not working on a shoe box case

But Im a designer, and I can't stand uglyness so I begun to project my own pc case.

I wanted this project basicaly to be an open design for others to share and modify on the future, so it had to be:

  • Affordable
  • Customizable
  • Good looking
  • Modular
  • common thickness of mdf
and because I really like tiny stuff,

  • Small as possible

List of materials :

3mm MDF or Acrilics
a power button ( i brought one from china)
a usb 3.0 internal cable for the front usb access (not shown on render)
cables from old pc cases

CURRENT MEASUREMENTS:

width : 212mm ~ 8.34 inches
height :410mm ~16.14 inches
Lenght : 362mm ~ 14.25 inches

(inches)

for those curious the system I'm going to put on this case is my current setup:

CPU : I7 4790
RAM : 16gb of ram - hyperx fury white dd3 1600mhz
STORAGE : 120GB 2.5 inch sandisk ssd plus
(used) 1TB 3.5 inch hard drive
even older 600gb 3.5 inch hard drive
POWER SUPLY : 500w ish old PSU
GPU : old and used Radeon 6770hd
cpu cooler : havik 140

CASE: old ~gamer~ look-like-a-car case

Project Sophia is for MicroAtx format, with 5 expansions slots for Crossfire / SLI (my board need the 5th slot for this so i assumed more people would like that)

This case supports up to 4 2.5 inch drives OR 2 3.5 inch drives with plenty space for another 2 or 3 ssds on the psu cover

This case has Mounting rails for triple 120 on front OR 2 140mm fans OR a single 200mm fan on front AND a single 120mm fan spot on the back.

This case has separeted chambers for the HD and the PSU

This case uses only 3mm mdf but any 3mm acrilics /ps board should work too

PSU clearence is 15cm (~ a small to normal sized psu)

Project Sophia has not : 5 inch drive support. i dont need it and it just got in the way of making it smaller.

before I leave you with the renders: Every comment helps! this project is not yet done and I'll apreciate your insights! I'll share the final project on the internet if it works so other people can use it. If you have any questions, want to see it in other colors or have ideias for the pci bracket mounting, please comment !
Thanks
smile.gif


project sophia - black

project sophia - white

project sophia - white

project sophia - raw mdf

the case is based on an internal structure secure by fittings and a cover with a cut that allows mdf to be bend covering the whole thing. also the front is a cutout pattern that is easly customizable and serve as air Intake with internal space for a dust filter. the side cutout is optional.

project sophia - raw mdf

project sophia - raw mdf

back side - stil working on the cutouts for the expansions slots
project sophia - raw mdf
 
#8 ·
excellent looking renders, subbed to see this come to reality
 
#9 ·
HEY GUYS I FINALLY MADE IT



so here what happened :
Every year some ppl at my university makes a 'fablab' style convention, with free lasercut and material for us to do whatever; it happens alongside a student design convention so i was there.
that was basicaly it. i got it for free
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and I'm very happy with my old hardware with a new case

so it went fairly well and theres a bunch of things I'd like to fix now

I'll post the pics of the process soon
 
#11 ·
wow that l ooks great! can you show some more pictures? i want to see the detail of that curved top panel
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#13 ·
so these are how they came from the laser cutter
i had made a piece to test the bend and it was bendable, but really stiff
Since I had to cut them at the same day (it was the last day of the event ) it didnt really mattered, so i had the cover cut anyway




i started assemblyng without glue at the local fair and let it there for the other students to see
i had to use some tape to secure it in place. the fold was too stiff







so here I had broke the pci bracket thing an i made another on hand.
that dint work very well but my graphics card is very old and im supporting it with another screw on the bottom, I'll post the pics about it later




here i was test fitting the hdd tray and i glued an old notebook hd cage on the back of the motherboard .. board.. ?







so at night i was here. the 4pin cable wasn't long enought, so i had to wait until monday morning to get one


ok were safe and the pc turns on
On the same day, I bought 2x 120 coolermaster black fans to put on the exaust side and on the cpu cooler. the 2 nzxt 140s i put on the intake because I wanted all white fans.. These will have to wait



see? it wont lay on the sides alone, so i had do screw the cover and the legs together but it turned out fine
 
#14 ·
here the details on the bent part:
I found a instructables article about bending mdf : http://www.instructables.com/id/Curved-laser-bent-wood/
I drew mine based on that, but i had no time to test it beforehand



Some things that gone wrong
basicaly I overloocked a lot of cable space.
some openings on the back side where to thin for any pin to pass trough, so I had to sand them to size.
The front IO was not really that smart. i had to sand for the power button to fit. and had to cut on the fan area for the usb port to fit, or else i would endup cutting the fan mounting grill.

the fan mounting grill really needs more support, i thought it looked pretty but on mdf that is kinda wobbly.... they are firm enough for the fans tho





what i didnt think of : the reset switch. sit it just lays there







the front mounting end up being really ok
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im happy it stays there without screws or anything. I shoult think of someway to secure it better





I can still use the top usb 3 on the front io without opening the front door in some cases.. that is until I buy a mesh..



that wasnt planned at atll
 
#15 ·
What im missing now:

the acrylic window. its basically an open case right now

the openings on the bend looks nice but i need to close them. they exaust to much air before going to cpu and graphics card. im not sure i like it.
I also need a new graphics card.. mine is ancient..

I'm putting a wordpress blog for updating this and for a donation button. the cutting plans will be available there
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#18 ·
ok a quick update

yesterday my pc turned off with a bang

turns out my really cheap extension cable was bad and melted like, for real

A trip to the local hardware store later and my pc is working fine.

I just ordered a new PSU from a national brand with good reviews and all black cables. I'll bee updanting the look of my pc then
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i also added a rgb led strip , that chinese cheap ones. I took pictures of the process. these strips use that controller and a 12v font. so it was easy to adapt a molex extension to this.

Now I'm kinda divided in the colors of project sophia.

I have a black and purple keyboad, a black mouse, and a black tablet, black everythings and the case will be painted black too. but I didnt like the way the purple coolor hits my yellow parts on the mother board :/ maybe with the new all black cables I'll be able to manage it but right now I'm not sure what to do.

I'm getting next year a razer tartarus chroma, to use it with my wacom as my keyboard (that thing is really usefull for digital illustration, wich is my work field) so it will just be a matter of a rgb keyboard maybe..
its not much of a deal actually but I am kinda sad that the purple color is not working :/

maybe if i can fine tune the colors on the rgb strip to match my keyboard will help? I'm not sure

I'll post the pictures in a minute
 
#19 ·
ok time for the photos

first, some pictures i forgot to show initally








oh here is how it looks after a week with that filter.

the filter is actually some pantyhose fabric. the white stuff is probabbly dirt and feathers from my girlfriend's albino cockatiel

here i was measuring how much space i have on the backside of the case and its a little over 2cm ( thats a little over 3/4 inch)


just earlier that day i was wiring my new ledstripe





obligatory flower towell photo
Here i was just feeding the led strip power to test it with the case closed. all good






oh yeah, i just had cut a acrylic window for my pc buut i managed to cut it in the wrong size so I hot glued it to the inside of the case
sorry for ****ty picture



everything was cool and all

but everything changed, when the fire nation attacked



But i got another atx extensor and its fine for now
I'm keeping the case open so I can keep an eye on it
 
#24 ·
came out nice, glad there wasn't an actual fire!
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