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  • Author Author: fmilburn
  • Date Created: Date Created
  • Views 4511 views
  • Likes 12 likes
  • Comments 19 comments
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3D Printed Raspberry Pi 4 Enclosure with Fan

fmilburn

The new Raspberry Pi 4 will not fit in any of the enclosures I have at hand and while doing preparation for a RoadTest I found that my Pi was overheating and throttling back.  A quick web search did not find what was desired and besides designing one seemed like a good learning opportunity.  The resulting design, done in Fusion 360, has the following features:

  • Pi 3 also fits the enclosure
  • Snap fit with no screws
  • Base enclosure has a plain, solid top
  • Camera slot can  be added to the print
  • Display slot can be added to the print
  • 30 mm fan can be added to the print

 

The additional features are added by altering their individual parameters which are kept in an easily accessible table.  Changes to clearances and key dimensions can also be changed if needed by modifying their parameters.  This might prove useful in printers with different resolution or if for example the case height needs to be extended to fit a hat.

 

The basic design is similar to one that was posted right after the Pi 4 came out.  This enclosure was designed separately from the ground up however and is not compatible.  To accommodate the difference in USB, multiple HDMI, etc. between the Pi 3 and the Pi 4  the case slots in these areas is open without dividers.  A camera slot, display slot, 30 mm fan opening, or any combination thereof can be added in seconds.

{gallery} Raspberry Pi Enclosure Print Options

image

Plain Enclosure

image

Enclosure with Openings for Camera and Display

image

Enclosure with Openings for Fan, Camera, and Display

 

Printing was done on an ANYCUBIC I3 MEGA with the following settings:

  • Layer Height = 0.2 mm
  • Wall Thickness = 1.2 mm (Wall Line Count = 3)
  • Filament = 1.75 mm PLA
  • Print Temperature = 200 C
  • Bed Temperature = 60 C

 

Total print time for the top and bottom is around 5 hours depending on the wall thickness chosen and the slots.  The photo below shows the Pi 4 mounted in an enclosure with a fan on top.  At this point a heat sink has not been added - just the fan.

image

As noted above, there was throttling prior adding the fan.  Raspberry Pi states that a warning is normally issued when 80 C is reached and throttling occurs at 85 C.  With the fan, temperatures did not exceed 72 C during the stress testing with the CPU at 100% for approximately 10 minutes.

 

Fusion 360 has amazing capabilities although I am still finding my way around it.  I am using the free one year trial for hobbyists.  I am very happy with the outcome and there are only a couple of small things I may change with the design:

  • Some of the openings are a bit large and could be reduced in size for aesthetics
  • The case width could be enlarged 1-2 mm as there is a tight fit on one side which makes removal of the top a bit hard

 

The fan also whines and I will probably cut some foam to fit between it and the case to dampen it.

 

Thanks for reading, comments and suggestions are always welcome.

  • in reply to dougw

    Hi Doug,

     

    I have had the version with the fan working for about 6 weeks now, using it daily, and the case is fine.  The fan is on constantly and the air coming out of the case is only slightly above ambient.  The case itself does not feel particularly warm so it is not surprising that there is no problem. 

     

    I suppose I should try the version with no fan and see what happens but then it will be subject to throttling which is undesirable for my experiments with Tensorflow.

  • I went ahead and enlarged the width of the case 1 mm and the height of the top by 1.6 mm so it fits the Pi better.  I also added a full circular cutout to the parametric settings for the full opening fanboys (pun intended) image.

    image

    I plan to use this case in a RoadTest of the Raspberry Pi 4B which will compare performance in face recognition using OpenCV to a Raspberry Pi 3B+.  Both will use the same SD card and be housed in the same case with a fan so they can run at full speed and to minimize differences other than the board itself.

     

    There are some nice cases showing up in the market now which minimizes the need to print your own, but this has been an interesting exercise in design nonetheless.  As for what could be improved, the clips / tab arrangement could probably be made to fit better although it is fully functional as is.  I am not sure the tolerances of my 3D printer will allow much more improvement.

  • in reply to balearicdynamics

    Hi Enrico,

     

    I don't plan to post it widely because I am using the free license and I do not understand what that allows and I don't want to lose my license.   However, I would be happy to send you or any active e14 members that have Fusion 360 the files.  Alternatively there is a way to work collaboratively but I haven't explored that.  As noted above it needs to be modified ever so slightly and I will try to make a new print with the changes in the next day or so.

     

    Frank

  • in reply to ntewinkel

    Hi Nico,

     

    Fusion 360 has different ways to model so it is possible to create things in sheet metal, cut from solid material, etc. as well as 3D print.  The only way I have used it however is for 3D prints.  If CNC cut from solid material this case would require 3 axis (or repositioning) to cut the opening for the SD card as an example.  As well, there would be undercuts for the tabs so it would require tool changeout.  And then there are the rounded edges on all sides.  Fusion 360 allows tool routing so that could be done I think but again I have no experience.  When 3D printed the slicer takes care of the raft (support) for the overhang on the SD card slot.  Angles of 45 degrees do not need a raft so that is the only one needed.

  • 3D-printerly challenged question here... can 3D printer models like this be run on a CNC instead?

    Seeing as there's no odd overhangs happening, it seems like it should be possible.

     

    I really should just retire early so I can actually learn how to use that CNC... hopefully the world will have Basic Universal Income by the time I run out of retirement savings.  image

     

    edit: or not retire, so I can buy a 3D printer image

     

    -Nico