making a computer case - tools? raw materials? problems?

[Icm76]

For a long time I've wanted to build a computer case (or two) from scratch, but I've always thought it would be too difficult to make something high quality at home using basic hand tools and power tools. My main concerns are that fabricating any design will require:

• cutting precise and accurately positioned slots, grooves and screw holes
• cutting straight and true panels
• welding (or some alternative joining) of a rigid frame
• bending and folding sheet material (inc. rolling edges)

Without access to a workshop with cnc machine tools and laser/water jet cutting it seems like the only option would be to pay for a fabrication service, and I think that would be extremely expensive. I will investigate this option further but if I can spend the money on tools that I can keep I would rather do so. In the meantime, I have some questions, and probably more to follow...

• do any of the experienced pros or hobbyists think this is a possible project to do at home? what are the major issues likely to be encountered?
• what tools would be required? what tools would be useful?
• is there a website that publishes competitive prices for raw materials? (aluminium is the most likely, but I might investigate others)
• can anyone suggest any hobbyist or project websites that would have useful advice or guides on fabrication techniques that would be applicable?
• any other thoughts on how to investigate this further?

N.B. aside from being swamped with house renovation projects, I need to do a lot more research and designing, so I wouldn't expect to start on anything until autumn or winter at the earliest.

[BillyGoat]

Edges are always something to consider.

I worked for an OEM years back who sourced a chassis from far east and shipped me a sample for evaluation. I undone the thumbscrews (nice touch) and lifted the side panel off.

20 minutes later and some awkward plasters, went back and painfully typed out a FAILED email to the buyers.

The edges were so sharp, without any pressure it made two clean cuts down the middle of both my hands - OWWWWWWWWW.

Shame they don't make knifes....would have brought a set for my kitchen anyday.

BG

[Icm76]

yes! I just edited my post to mention rolled edges, I've seen some vicious cases in the past. Thankfully most cases these days have rolled edges or adequately smoothed edges, even the really cheap ones,

[kellys_eye]

Start with a ready-made case and 'adapt' it as required?

Why use metal? Try sculpting perspex - it can but cut, rolled, joined (invisibly) and in lots of colours.

How about having one machined (CNC'd) from a 'lump' (plastic or metal)?

I put a PC in a wooden bread bin once - looked pretty good too! Tasted awful though.

[Icm76]

Fair ideas, but not entirely suited to what I have in mind. I may be able to pinch some small bits off old cases like panel catches, but the grand ideas involve unusual layouts and features, so recycling an old case for the basic chassis won't work.

Assuming I go ahead with this I'm undecided on materials. Aluminium is probably the most sensible choice for a metal case in terms of cost and keeping it light weight and relatively easy to work, but I've a few ideas for others e.g. titanium would cost quite a bit more for the material, but I believe it wouldn't much more or less expensive to machine than aluminium.

Plastics I haven't looked into yet, but I am vaguely aware that certain types of acetal can be usefully machined. Perspex I would probably only use for a window if I decided to add one. Overall though I don't know how to get a nice looking finish on the outside of the case if I mainly use plastics.

[BillyGoat]

Watch out for some plastics.

Again, seen issues in the pasts where certain mixtures of plastic are great generators of static electric - the arch villan of computer parts.

If you want some inspiration of what people do, look here: http://www.mini-itx.com/projects/accordion-itx/

EDIT: Not the link I was looking for - look on the RIGHT hand side, there is a LONnnnngggg list of projects to see!!

BG

[Cannyfixit]

Watch out for some plastics.

Again, seen issues in the pasts where certain mixtures of plastic are great generators of static electric - the arch villan of computer parts.

If you want some inspiration of what people do, look here: http://www.mini-itx.com/projects/accordion-itx/

EDIT: Not the link I was looking for - look on the RIGHT hand side, there is a LONnnnngggg list of projects to see!!

BG

Thats a cool accordion ,when i built my 1st and only pc i looked for inspiration out of the norm and found this

but ended up settling for a standard case

[Hitch]

The thing is, these things are machine made, cnc turret punches, lasers, specialy made punches and dies, the cases can be turned out say 100 an hour, but for a man to stand there and deburr the edges on such thin material would need 10 men to keep up, perhaps doubling the price of each case.

A lot or the rolled/hemmed edges may well be more for strength as much as safety.

Theres quite a lot to working sheet metal, especially to any level of accuracy.
Getting it made to your spec incurs money, quite easily run into hundreds for a one off.

The programming, the setting up, loading of tools etc into machines often takes 10x the actual time to do the job where 1 offs are involved. With material and cutting cycle time at £1 (for easy math) you end up like this-
1 may cost £201
2 may cost £102
4 may cost £54
40 may cost £6/unit.

Theres nothing to stop you designing and getting it lasered yourself, and getting it bent up elsewhere.
But you then need to think about tooling available where you take it. Something like a computer case would be a pain to bend on a machine like a cnc press brake which most sheet metal working shops will use.