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I've never worked with sheet metal, but have a good understanding of the principals.Quote:
Originally Posted by individual
Yes, there are many types of glue that could be used for bonding the sheets. This also makes the side covers very strong and rigid.Quote:
Originally Posted by individual
You've got a very good understanding for someone who hasn't worked with sheet metal before, very impressive :)
I've been talking to some of colleagues today and we've come to an agreement that the prototypes will have to be lazer-cut, then bent and folded, to save the manufacture of punches. Even with lazer cutting, it will be costly. most likely around 300-400 alone for just the lazer cutting (I know from previous work I've had done). the only issue i can see, is bending the side panel latches, more than likely will have to be done in a special hand press.
Thinking more and more I may even do the prototype in aluminium, and do most of the bending and folding by hand.
With the side panel issue when using the 5.25 cage for structural support, that could easily be fixed by simply making the catching flange on the side panel slightly higher.
I will have to modify some things on the case very slightly to get it produced, but it is do-able, and it will be done :)
SO I tried test bending some aluminium 6061 sheets today, 2mm thick, has a very large tendency to crack when bending, so I'll have to use steel, which is going to make this f***er heavy, at least 10 kilos.
I've modeled the 5.25 cage alone and in steel the mass is 1.2kg :O
http://i13.photobucket.com/albums/a2...psa67489da.jpg
Also, with the corners, this is what i was talking about.
http://i13.photobucket.com/albums/a2...psdac23ebb.jpg
http://i13.photobucket.com/albums/a2...psefacbd8f.jpg
Then simply have your corner support idea behind that, riveted in.
OK I'm doing the motherboard tray, which is BY FAR the most complicated part of the design.
A few things I've discovered, the rear IO mount (where the I/O shield clips into) can be a maximum of 1.32mm thick and a minimum of .93mm thick. So I'll have to change that to 1mm material.
I have to ask, I can find all the details I need for the HTPX form factor mounting holes and I/O shield, but I can't find any details on PCI mounting :/
I'm after the PCI tabs that slot into the mobo tray, their placement in relation to the motherboard mounting holes, and of course the dimensions of the PCI slots, and placement of the screw holes. basically everything PCI I still need. Most of your dimensions are solid, but I want to double check everything especially when things start to get made.
Well if you have the exact dimensions of a 10 slot I/O shield you should be fine. Fix the I/O shield to the rear of your case and then start to place the motherboard holes from there (if you know the motherobard I/O measures. If you do not have the complete measures of a 10 slot I/O shield I think I could give you a help. I think I have them in SolidWorks and I'm also waiting for a 10 slot I/O shield from danger den which should be ideal for your needs, I could measure it for you.Quote:
Originally Posted by individual
Also, check out www.grabcad.com and I'm sure you can find a correct I/O shield there :)
I'll try to send you a couple of measures as soon as I get home. Can I ask you if you'll be so kind to share HPTX form factor mounting holes here or via PM? I really need them :)
Thank-you
Use aluminum 5052-H32 (easy to bend): 1mm or 2mm is up to you.Quote:
Originally Posted by individual
Awesome ill look into it :) ill use steel for the prototype still just because its cheaper but if the case takes off ill switch to 5052 :)Quote:
Originally Posted by JoanchimMartin
Luckily i now am the system administrator for a custom aluminum siding manufacturing company.
I will hopefully see them sometime this month and will have one of the engineers take a look at this for me and quote me a cost to make it.
Ive been eyeballing this thing since you first drew it up. Maybe ill be the first to build it :)
Quote:
Originally Posted by Gimmpy224
It's a competition!! Lol if you can build it, awesome, will get done faster that way. I'm estimating as a prototype around 600-700, if you get punches made about 1k. I'm transferring all the components to inventor as final measurements, so if you get a quote and you want to build it PM me for the drawings :)
As soon as I get home ill upload them for you to this thread :)Quote:
Originally Posted by .::NeO::.
A collaboration would be awesome! Helping one another, bouncing ideas, and finding solutions to problems would be made a lot easier! Of course, I will help as much as I can, and I'm sure there's a lot of enthusiasts that will also like to help as well. Be prepared for some criticism though, good as well as bad. :up:
I'm liking where this is going
http://i13.photobucket.com/albums/a2...ps4c0b9786.jpg
Here you go Neo :)
I went to my local computer store and asked if they had any spare/damaged/cases left over from upgrades lying around, got some generic case, but the case is solid so I'll compare the measurements on that GrabCad model to my own measurements and see how equal they are :)
EDIT: I'm not 100% sure if you need every one of those holes, but it cant hurt incase you swap to an EATX or even an ATX at some time.
Hi individual,Quote:
Originally Posted by individual
thank you for sharing your knowledge with the forum :). I'm at work now but as soon as I get home I'll post a picture of what my actual motherboard tray and motherboard holes look like, because from the jpeg you posted I can notice some differences (especially for the HPTX form factor holes). Maybe we can compare our holes position and see what the differences are.
Also, I'm happy to inform you that my order from frozencpu.com is arrived in Italy, I should receive my Danger Den 10 slot I/O shield in the next days so I can measure it and share the informations with you and the rest of the forum :)
.::NeO::.
I have an issue with the motherboard tray....In this document http://www.pc-junky.com/pdfdocs/EEB_..._spec_v3_0.pdf , it says that the bottom opening of the I/O hole, is .088" or 2.25mm BELOW the base of the motherboard/standoff height.
Which is correct for this generic case, and my main Coolermaster case.
Which, the issue then becomes, the flange on the IO peice, that folds inwards towards the motherboard tray, wont fit with standard 6.5mm standoff's (being that the bottom of the opening would only be 4.2mm away from the motherboard tray, WHICH is normal in most cases (lol, double take) but because of this design, have to find a way around it.
Solutions:
Use bigger standoffs. The ones I have are 6.5mm high but i'm not sure if this is the same for everyone.
http://i13.photobucket.com/albums/a2...02BA0D00EB.jpg
don't bother to change or add flange, just industrial glue straight to edge.
Wrap the flange 180 and turn it into an extended hem, then rivet onto actual motherboard tray.
http://i13.photobucket.com/albums/a2...psd7951439.jpg
That's fantastic news :) because trying to find standards is ridiculous, and making a motherboard tray with an IO shield and PCI slots is more complex than I would have thought haha. I know why they're so expensive now haha.
The hole placement data is from Intel themselves :) on their SkullTrail board they released (d5400xs, which is XL-ATX I believe). the extended holes for HTPX were found somewhere on this forum :)
Just found this, after 80 google pages. I'll have to see whether its consistent with my findings tomorrow :)
http://i1133.photobucket.com/albums/...asurements.jpg
I've called up Thermaltake Australia this morning and explained to them and asked them for the form factor standards documents for all areas of chassis design, and I explained to him about the case and who designed it and how it came second by merely 1 vote in the case design competition, he seemed to remember the case and said he would go talk to the engineers and see if he can get me the documents. Fingers crossed!!
Awesome news!Quote:
Originally Posted by individual
as promised I share with you and the forum my Micro ATX, ATX v2.2, E-ATX, HTPX motherboard tray holes placement.
I measured the distance from a hole to another, instead of starting from a single point like you did, but you should be able to compare my holes placement to yours. I'm pretty sure that Micro ATX, ATX v2.2 and E-ATX (SSI-CEB/SSI-EEB) holes are correct (i took specs from http://www.formfactors.org/developer/specs/atx2_2.pdf and from some documentation at Silverstone website).
I'm not too sure about some of my HPTX holes and I also can't find some HPTX holes in your model.
HPTX is not a standard form factor and is owned by EVGA so no free documentation sadly, but I think that me and you (and the forum members) could sort that out.
http://img687.imageshack.us/img687/2622/mbtray.png
Uploaded with ImageShack.us
As for the 10 slot I/O shield plate I ask you just to wait a little bit since the package from USA to Italy will take a bit to arrive.
I look forward for your feedback.
Best regards,
.::NeO::.
There doesn't seem to be much discrepancy between our hole placements, and there is a 0.1mm tolerance on hole placement generally (which is absurd, I don't like working with tolerances that big)
In any case, I have sourced documents and cad files Directly from a case manufacturer :) These guys have done thousands of cases from military to every day ccustom computers. Could even get this built through them lol
http://www.protocase.com/pdf/How_to_...ems_092010.pdf
http://www.protocase.com/pdf/Downloa..._3D_SLDPRT.zip
http://www.protocase.com/pdf/Motherb..._CAD_files.zip
EDIT: With this in light and the motherboard issues getting sorted, the case is coming along very smoothly, and has also given me ideas for a few aesthetic case designs (im not sure how my ideas came from this case, they are completely different)
Michael, I spoke with Thermaltake again this morning, they couldn't deliver documents unfortunately but no matter I got what I was looking for elsewhere, but the lead designer said he was the one originally pushing to get your case into production ( I assume you've spoken to thermaltake before? or maybe from the competition) so there is still hope there too.
EDIT 2: I'm trying to get the EVGA forums admin to give me the hole placement dxf file, because i know he has one, and it's from their design ducoments.
Also, when this is done I'll post a new thread of chassis building resources and documents.
Yep, I also checked and basically all the major holes are there in both mine and your design :). The only ones I'm missing are those that in your drawing goes from 0 to 177.8 and from 0 to 191.77.Quote:
Originally Posted by individual
There's a hole in your design which is not there, and is the hole that in my design goes from 11,43 to the left (i marked it in green)
http://img90.imageshack.us/img90/1619/hptxpan.jpg
Uploaded with ImageShack.us
.::NeO::.
After utilizing data from standardized sources, the IO panel and PCI slots all line up and fit perfectly :)
http://i13.photobucket.com/albums/a2...psfc7e792c.jpg
EDIT: Mike64, not that I didn't trust your skills and accuracy, pretty much every thing on there is spot on, It's just a habit to be 100% sure for myself :) I'm ever so slightly modifying dimensions just to make it all to whole numbers as most I can, without affecting component placements of course.
Neo thank you for the measurements :) I'll be sure to add that hole in. Did you measure all them by hand? with calipers I'm assuming?
I'm happy that you are checking the dimensions. I tried my best to ensure that everything is correct, but mistakes do happen and I'm no expert. Also, as you have already discovered, it's not always possible to replicate the design in the real world and dimensions will have to be changed. Good luck! :up:Quote:
Originally Posted by individual
I'm almost done the modeling, got everything but the radiator holders and the PSU bezel done, then i'll go over everything with the collision tool and make sure nothing interferes :)
So I have some very good and very bad news. It depends how you look at it.
http://www.caselabs-store.com/magnum-sth10/
I got quoted by caselabs and protocase and legend to manufacture micks case, and the prototyping would cost well over 1500 which is including materials, after that you could do production runs and knock them off fairly cheap though, about 70 per case, then sell them as you wish.
That link i posted, Is a case by caselabs, which is essentially just a larger, more modular version of Micheal's case. I was excited and heart broken to find this case to be honest.
I'm not really sure what it means yet.
Wonder where they got their design idea from? :rolleyes: It's not as pretty as mine, but it's probably easier to manufacture, and looks fit for purpose. :clap: I might even get one myself if my design is too expensive to produce. :shakes:Quote:
Originally Posted by individual