[Build Log] Metroid -A 3D printed computer case

[thorkon]

Hi guys, I'm 8-Bit Builder. I've been doing this for about 10 years now and just starting up my newest build. I build cases in the an old pixelated style as you will see shortly :D.

      I've been wanting to build a Metroid computer case for about 7 years now but plastic was always too expensive ($1 a cube) compared to .08 cents a cube of wood which is what all my previous PC mods are made out of. Once I found out how accessible 3D printers were, I jumped head first and picked up a Maker Select. After a few months of non-stop printing it dawned on me that I could make the Metroid computer case I've been thinking about for such a long time. Normally I spend about 200-250$ in wood/paint but 3D printing plastic is really cheap in comparison, about $80 in plastic. I'm also planning on having a really cool light sequence on the inside of the case to get the red effect of the in game Metroid. Being my first foray into a 3D printed computer I'm sure I'll run into issues but look forward to overcoming them. This will also be my first time with programmable LED's so it will be a learning experience on that front also! I'm going with an ASUS STRIX for the Aura Sync capabilities since this case is going to have a big focus on lighting. The more advanced lighting will be done with the Tinkerboard.

Expectations:
A strong gaming pc
100s' of LEDs programmed inside for a light show
95% 3D printed

Components:
ASUS has sponsered/supplied me with components for this mod (Really appreciate it) and also in the past on my Airship PC Case seen here: https://www.youtube.com/watch?v=Cz5muWnFMmg

ASUS ROG STRIX X370-I GAMING AM4 AMD X370 SATA 6Gb/s USB 3.1 Mini ITX AMD Motherboard

ASUS GeForce GTX 1080 TURBO-GTX1080-8G 8GB 256-Bit GDDR5X PCI Express 3.0  

16 GB of ram
1TB SSD
Asus Tinkerboard with a few hundred LEDs programmed in a cool light show

And heres some photos of my past work:

Airship from Final Fantasy

Link from Zelda

And a 3D model I've printed, Calcifer from Howl's Moving Castle

Ok on to the build! This is what I'm building (modeled in 123Design/Tinkercad):
Metroid from ...Metroid!
 

The modeled case

My first idea of how the components will fit

I started printing and doing test pieces to make sure I had it down pretty good and to test strength of the frame. Needless to say, it holds a LOT of weight (I weigh 185lbs)

I've got the printer going in earnest on the final design now. The printer will be going non-stop for about 2-3 weeks to get all the pieces done. I'll be back soon though with photos of attaching sections together with glue and 3D pen welding! 

If you have any questions or ideas, feel free to ask

[thorkon]

Also; I was impromptu'd interviewed by LTT in 2016 about one of my computer cases here if anyones interested in seeing me stumble my way through it! Timestamp is 4:41 if it doesn't work.

 

[thorkon]

Back with a few updates. I'm printing in earnest, and got a few progress shots and issues even, but nothing unsurpassable.

This is a gif of a lighting test for the build. I wanted to verify Red Leds would go through green plastic without to much color distortion. Alls well on that front

Heres the printer starting on a 48 hour print job.

This is the base of the metroid which will support the weight of all the components. Just prepping gluing it and clamping.

And this is my work area. Off to the right is my second printer with the Airship pc case nearby.

[thorkon]

ON to some special super glue made for 3D PLA and a 3D pen to weld the pieces together. The glue is probably fine but I'm gonna play it safe and double up on strong connection points.

The glue

3D pen action

After 3D pen

Give em the clamps!

Finished base

Baby for scale

[thorkon]

This post is about printer problems

This is how it looks starting. This is about 3 hours into a print of 1 of the 14 sections left

A little futther in the print, about 9 hours

Aaaaand heres the issue at about 12 hours in. The tube that guides the plastic let loose while I was away from home and just shot the plastic everywhere. Usually on 3D printing you can resume from where an error happened but due to the nature of this design, the pieces have to be complete in 1 shot. So this is about 12ish hours of progress loss and plastic loss

Round 2 at trying the same print after I fixed the issue. Using my Fire light to keep it lit up at night for the timelapse I'm making.

ANNNND heres issue #2. This is hard to see, but at 46 hours in on this print WITH ONLY 2 HOURS LEFT!, I got a layer shift. A layer shift is usually because a belt slips or a cable got caught on something. In this case, the cable got caught on the section of the plastic as it was printing. It prevented the head of the printer to move to its correct position so it started printing to the left by about 4mm. i caught it after it happened in about 10 min. but it was too late. 46 hours loss and about 11$ of plastic loss ;_;. Since this happened, I don't print the sections more than 4 columns of cubes high (88.8mm), that way I don't take such a large hit of loss of time. Its not noticeable in this photo of the layer shift but i had to discard this piece.

These issues combined with my 2nd printer also running into problems (was down for 5 days while replacement parts came in), was a hit in my sails of progress, but I've been back on track in the last day or so and got them both running. About 7 days of non-stop printing should get the the top of the case complete. I'll be back in a day or two to update progress with the components being layed out inside the base, and will probably ask for opinions on what looks best. See you guys then!

[thorkon]

Heres a component placement update:

The ASUS Turbo 1080 just by its lonesome

The ASUS STRIX-370I alone also

But not for long! These are testing "legs" to hold up the motherboard. I'll make some beefier/sturdier ones soon, but I really do like the 45 degree angle of the STRIX 370-I toward where the window will be. Not often I get to do a motherboard at an angle like this

The bottom is for a 200mm fan, just using one of my placeholder fans atm to test with

Bottom with no fan frame base

With base

With fan

[thorkon]

Back with some more things:

 

Working on the "teeth" which are what hold up the case from the floor

 

Printed in tranparent red and white, with a hollowed out point for leds to light up

 

 

The teeth going through quality control (not sure how to embed gifs/youtube links on here so just a regular link for now:

Teeth in place

 

This is neat, this is heat changing plastic. Its brown at room temperature but turns green as it warms up. In this photo, I drilled the holes a little bigger and the friction from the drill heated the end up to green as you can see

 

Lastly, a new issue. This is a partial clog in the nozzle where not enough plastic comes out. I cleaned the plug and had to toss this piece.

[thorkon]

Working on the top frame now.

Heres the base in pieces

Clamping it together

All said and done with the lower section

I'm still waiting on the printer to finish the rest of the sections so will have whole frame done in a few days

Experimenting with different wire covers I printed

[thorkon]

Getting near the home stretch!

Heres a test lighting of one of the feet. No cable management yet...ha

Side being built up:

Not fully complete but just an idea how the window will be

I'll be back when I have the whole top finished with fans and whatnot. I'm gonna start working on getting the leds wired in

Heres a test run with them shoddily taped on the inside

 

[thorkon]

Finished up the frame of the top!

Couldn't use any vertical clamps due to the say its smooth on the inside, so had to use some weights to help glue it down.

Baby for scale

Adult for scale

This is my wife staying "awake" past her bedtime trying to help by routing the pc wiring on the inside

Now I'm moving on to the LED wiring on the inside. Its going to be awhile of wiring and soldering... Heres what a pattern/schematic of the led paths

 

[lieder1987]

very interested to see the final product.

[thorkon]

Back now that I'm done with the wiring. Oh boy, was this an adventure. I've rarely done soldering/wiring and this has definitely increased my skill with it ha. There will be gifs of the lighting, I'll provide a link if the message board isn't showing it natively.

So my first test was my lazy test, which to say was I was hoping i could just fold the led strip to make 90 degree turns but I didn't like the way the lights would repeat flash whenever it came to a bend...

GIF of Light issue

https://imgur.com/IeL0tHB

I decided to cut the led strip and solder whenever there was a 90 degree turn. Heres the same layout, but with wiring instead of folding

GIF of Light fixed
https://imgur.com/Am1TJAy

Next is some wiring shots
Splitting off the led strip

The monotonous monotony of stripping wires and tinning wires

The finalized wiring on the inisde with everything hotglued in place. I'll need to print some covers to hide the wiring and clean it up.

and finally one section lighting up in the dark
Gif of section lighting up

https://imgur.com/KNzvVWC

Next is programming the ASUS Tinkerboard so that the led strips will run on seperate timings. I'm just delving into this so should be interesting

[SupaKomputa]

Amazing! thanks for sharing

[thorkon]

I didn't know much about it, but they offered it. I will see what I can do, but I'm still new to coding so will have to see how it goes.

[thorkon]

Just a small update of all the lights running
heres a link if gif embed doesnt work: https://imgur.com/VMuIZOR

Still working on trying to program the coding so they run separately atm

[thorkon]

Turns out programming isn't as easy as I had hoped. I have a friend or two giving me a hand. In the meanwhile, I picked up 2 more sponsors! This is greatly appreciated and welcomed.

First off is GEIL with supplied 2x8gb SUPER LUCE 2400 DDR4 RGB Ram

Next is ThermalTake who graciously supplied RGB fans, PSU, and a sweet CPU cooler

Engine 27 CPU cooler (first time for me seeing an all metal fan, looks awesome!)

Thermaltake Toughpower Series PSU SFW 600W

Thermaltake Riing Plus 12 RGB Fans + TT Sync Controller

[thorkon]

Back again! I've been doing small things that didnt warrant many photos (trying to learn to program, ended up having my 2 buddies help me), and rearranging computer components. 
I'm nearing completion though! I will probably have 1 more update after this then it will be final photos and a time lapse video of the build/3D print process. My buddy is working on the music for that video atm. Anyway, on to the smaller update here:

This is the rear of the case. Its fitting the Thermaltake Riing RGB fan. I wanted to keep the fan removable because I need to get my hand in the computer case to plug the fans in once I put the top on. I ended up using magnets to hold the fan in place (located at each corner). 

This is the top of the case with another Thermaltake Fan. This is permenantly installed in the case no need for removal here.

This is experimental. I'm using translucent red plastic to use as pseudo cable sleeves for psu/power button/Asus 1080 card. I think it looks good, but what do you think?

Also you can see I went with Thermaltakes Riing Cpu cooler. I was afraid it would be too tall but it is about an inch short of hitting the top of the case so no worries.

[thorkon]

Probably last update until the final photos and video! I'll have it at PAX East 2018 if anyone is going to be there by chance.
Got the lighting done! I have it wired into the PSU so it doesn't need additional outlets to be plugged in.

This is the window side. Just printed some flat sides to cover up gaps the acrylic window leaves.

These are little "feet" that help guide the top frame onto the body. They are angled so the top section slides on them.

Next is I decided to self-promote on the SSD since it was looking bland anyway

My finalized wiring job

Be back in a week or two with the final photos! (probably post video a little after that).

[SilicateWielder]

Wow, this is neat!

 

I'm working on my own 3d printed computer case project and was wondering what material you're using, also do you ground your components, and if not, have you had any stability issues, or issues with ESD?

[thorkon]

I'm using PLA, going to see how it goes. Maybe try PETG out at some point for my next mod, but if PLA holds strong I'll just keep with it. So far I haven't had any issues. The electronics are grounded through the PSU's ground (from what I've researched, this is the majority of where your computers grounds come from). I've only been running it for a week now though, but I don't expect much issue.

[thorkon]

Heres the finished video. It shows the whole computer being printed. I'll be back with the photos soon!

 

[thorkon]

@Pangea2017 Thanks, not sure how I pulled that off, ha. Fixed!

[thorkon]

Large photo dump inbound!!!!!
Specs: 
-ASUS ROG Strix X370-I

-ASUS GTX 1080 Turbo

-GeIL 16gb DDR4 Super Luce RAM

-Thermaltake SFW Toughpower 600w fully modular PSU

-Thermaltake Riing RGB Fans (120mm, 200mm, Cpu cooler)

[lieder1987]

Bravo.