3D printed computer case

[Rezzaled]

Over the top idea, what if one 3D printed a computer case out of copper or aluminum? By using CAD software and 3D printing one could design the shape of the case to be in direct thermal contact of all heat sources on the MOBO, CPU, and GPU. One could then also explore more intricate patterns and textures, say sponge like for maximum surface area for cooling.

 

Challenge for Alex, 

- Using topology optimization, design, print, and test a 3D printed metal computer case, that will function as the direct heat sink for all major heat sources in the system, support all major components, and that has the highest possible surface area with least possible metal volume used for printing.

[vong]

6 minutes ago, Rezzaled said:

Over the top idea, what if one 3D printed a computer case out of copper or aluminum? By using CAD software and 3D printing one could design the shape of the case to be in direct thermal contact of all heat sources on the MOBO, CPU, and GPU. One could then also explore more intricate patterns and textures, say sponge like for maximum surface area for cooling.

 

Challenge for Alex, 

- Using topology optimization, design, print, and test a 3D printed metal computer case, that will function as the direct heat sink for all major heat sources in the system, support all major components, and that has the highest possible surface area with least possible metal volume used for printing.

Why 3d print when CNC will do a better job?

[Rezzaled]

CNC is limited in what shapes it can do. Some of the shapes possible with 3D printing simply are not possible with a CNC machine.

[foldingNoob]

youd prob be better off bending heatpipes to hit all these thermal points.

[Rezzaled]

I did preface by saying "Over the top idea". Plus, a copper heat sink of sufficiently large surface area for a similar volume as a heatpipe could more effectively radiate heat.

[vong]

5 minutes ago, Rezzaled said:

CNC is limited in what shapes it can do. Some of the shapes possible with 3D printing simply are not possible with a CNC machine.

Don't need to do intricate shapes to make a heatsink though so no point. Sure printing would be interesting but it's just a waste of resources for no better result.

[Rezzaled]

No, intricate shapes would not be necessary with heat pipes, but the point would be to do something interesting. It wouldn't necessarily be a waste of resources with no better results either. With topology optimization you can compute shapes that use as little material as possible. In fact in doing so I'd wager you could use less metal than typically used in a computer case and air cooler combined. If you are not familiar with topology optimization I'd recommend looking it up, it's F-ing cool and the wiki page has a great introduction to the idea.

[vong]

42 minutes ago, Rezzaled said:

No, intricate shapes would not be necessary with heat pipes, but the point would be to do something interesting. It wouldn't necessarily be a waste of resources with no better results either. With topology optimization you can compute shapes that use as little material as possible. In fact in doing so I'd wager you could use less metal than typically used in a computer case and air cooler combined. If you are not familiar with topology optimization I'd recommend looking it up, it's F-ing cool and the wiki page has a great introduction to the idea.

How interesting do you want to get? Heatsink cases have been done, don't think you can get any better than a square/rectangle functionally. When it comes to cooling, more is better.

[narrdarr]

40 minutes ago, vong said:

How interesting do you want to get? Heatsink cases have been done, don't think you can get any better than a square/rectangle functionally. When it comes to cooling, more is better.

True but I haven't seen one done very well.

 

I think it mostly because the approach to the idea has been wrong the who'll time. Everyone think about the integrating the heatsink or other cooling solutions into the case. When they should be thinking how to interested the case into the cooling solution. 

 

I have a hand full of ideas for case in many flavors, but haven't touched CAD or any other 3d modeling program in 20 years.

 

 

OP if maybe you want to collab a bit. DM.

[Rezzaled]

I'm envisioning more of a sponge metal structure. You're right, more is better, but it doesn't just have to be mass that you have more of. Yes, you can get better than square/rectangle functionality, the purpose of having fins on heat pipes is to increase surface area for heat dissipation into the air. The most important factors for heat dissipation are surface are and air flow, that's why all sensible heat sinks have many fins.

[narrdarr]

13 minutes ago, Rezzaled said:

I'm envisioning more of a sponge metal structure. You're right, more is better, but it doesn't just have to be mass that you have more of. Yes, you can get better than square/rectangle functionality, the purpose of having fins on heat pipes is to increase surface area for heat dissipation into the air. The most important factors for heat dissipation are surface are and air flow, that's why all sensible heat sinks have many fins.

It should work fine l. Fins are just more cost effective to make. As long as you have a enough surface area to transfer heat and enough airflow through the median you should not have a problem. May not look the same as you picture in your head, but you could test the idea with copper wool. Then refine the cosmetics later.

 

[LogicalDrm]

-> Moved to Cases and Mods

 

If you want to make video suggestion, please use official thread:

 

[suedseefrucht]

8 hours ago, Rezzaled said:

say sponge like for maximum surface area for cooling

A big surface is not the only important thing for good cooling. You will also need a good heat conduction. So a sponge is not that good.  Something like a tree would be perfect. A big diameter conductor at the heat sources plitting into smaller heat pipes which also split into even smaller heat pipes and so on.

[Rezzaled]

4 hours ago, suedseefrucht said:

A big surface is not the only important thing for good cooling. You will also need a good heat conduction. So a sponge is not that good.  Something like a tree would be perfect. A big diameter conductor at the heat sources plitting into smaller heat pipes which also split into even smaller heat pipes and so on.

This is true, but this could easily be a modification in the design process. I still think a sponge texture would work well, but yes you do need a sufficient thermal mass for thermal transport. Have the connecting surface be a slab of sorts but then have that transition to a structure that is better for heat flow. Again there may be better structures and geometries to do this with, sponge was simply first to mind.

 

6 hours ago, LogicalDrm said:

-> Moved to Cases and Mods

 

If you want to make video suggestion, please use official thread:

 

My bad, I'll keep that in mind for any future posts

 

10 hours ago, narrdarr said:

It should work fine l. Fins are just more cost effective to make. As long as you have a enough surface area to transfer heat and enough airflow through the median you should not have a problem. May not look the same as you picture in your head, but you could test the idea with copper wool. Then refine the cosmetics later.

 

That could be a good proof of principle approach

 

10 hours ago, narrdarr said:

True but I haven't seen one done very well.

 

I think it mostly because the approach to the idea has been wrong the who'll time. Everyone think about the integrating the heatsink or other cooling solutions into the case. When they should be thinking how to interested the case into the cooling solution. 

 

I have a hand full of ideas for case in many flavors, but haven't touched CAD or any other 3d modeling program in 20 years.

 

 

OP if maybe you want to collab a bit. DM.

As much as I'd like to collaborate I currently do not have the time to do so, but feel free to use my idea.

Edited November 11, 2020 by Rezzaled
Wanted to amend the thought.