WOODSTOCK

I created several computer cases that utilize a “living hinge” design achieved through laser cutting. These cases are made out of readily available, low-cost plywood and feature smooth large-radius bends usually achieved through expensive sheetmetal press dies.

Due to a shortage of online information, I refined the living hinge pattern relief and laser cutter settings over many prototypes. I eventually found a mathematical relation that produces consistent living hinge patterns capable of tight radius bends. I designed all cases using the sheetmetal tools in Fusion 360 and generated flat patterns of all panels before adding the cut patterns.

SC-09

SC-09 is an open-source computer case designed to best combine price, space-efficiency, and functionality. The fundamental design takes cues from many previous projects - namely, the use of acrylic sheets for structure, flexible component mounting points, and a modular flat-packed design. All 3 were essential in reaching a low target cost as it enabled a reduction in total part count, shipping costs, and production time.

Audience

While a somewhat niche audience, the small form factor (or SFF) community expressed considerable interest in the project’s first prototypes/concepts. I used the subreddit /r/sffpc, one of the largest communal forums for the hobby, to seek feedback and constructive criticism from the community and applied it to the final product. I was also able to leverage the first few buyers as volunteer product testers, who gave specific feedback about the build process and offered improvements.

Final Implementation

I wanted to create the most complete, seamless experience possible for the end user. The digital instructions were modeled after the design ethos of Lego/IKEA manuals, and the case is shipped flat packed with each individual panel protected. The design pays careful attention to space efficiency in production+transport, and fits tightly on a standard 16x24” sheet of cast acrylic (to be laser cut) and into a USPS Priority medium box. The layout of parts, both laser cut and 3D-printed, is meant to reduce heat warpage and increase strength where possible while remaining easy to machine on any consumer machine.

Notable Features

• Compact 9L External Volume with ITX GPU and small tower CPU cooler compatibility

• Modular drive mounting slots, up to 9x drives in parallel

• Twin 80mm Exhaust fans, 1x 120/140mm intake

• Fast and straight-forward assembly process (panels/hardware pre-threaded and threaded inserts installed)