Overview
A personal manufacturing project spanning two iterations in 2025. The goal was to design and fabricate a custom PC chassis that combines specific aesthetic requirements with functional thermal performance.
What started as a flawed course project in Spring 2025 evolved into a highly precise, custom-engineered gift in Fall 2025, solving complex constraints around material properties and hardware standards.
Tools
SolidWorks, Adobe Illustrator
Method
Laser Cutting, 3D Printing
Material
Basswood Plywood + Varnish
Phase 1
The initial iteration was a final project for my Engineering Design course. I used Fusion 360, but due to my inexperience at the time, I didn't fully model the internal components.
The Failure: The design lacked a proper mounting bracket for the GPU, forcing it to hang precariously from the backplate. Worse, I ignored environmental factors, the heat from the components combined with ambient humidity caused the unsealed plywood frame to warp significantly. This taught me that valid engineering is far more than just "drawing a box."
Phase 2
For the second iteration (a birthday gift for a friend), I started from scratch using SolidWorks, strictly following an assembly-based workflow. I faced several unique challenges that required custom engineering solutions.
1. The "Zero-Tolerance" Strategy
I discovered that online ATX specifications didn't match my physical Micro-ATX board, leading to a wasted initial cut. I switched to manual verification for all dimensions.
To combat the warping issue from Phase 1, I utilized the laser cutter's kerf (cutting width) to my advantage. I designed the mortise-and-tenon joints with zero tolerance. The slight material loss from the laser created an interference fit that, when combined with the swelling effects of the surface varnish, resulted in a perfectly rigid, interlocked structure that resisted internal stresses.
2. Inverted Airflow Schema
Constraint: The user owns cats and has carpeted floors (dust/hair risk), but wanted top-mounted IO ports despite short front-panel cables.
Solution: I designed an inverted motherboard layout.
- GPU Fans Face Up: Acts as the primary intake, pulling clean air from above rather than dusty air from the floor.
- Top IO: Inverting the board moved the headers closer to the top panel, solving the cable length issue.
3. Personalization
Using Adobe Illustrator, I processed photos of the recipient and their partner, converting them into high-fidelity SVG vectors. These were laser-engraved onto the chassis panels, turning a functional computer case into a deeply personal gift.
