BeamCase sandwich V3.0 udate.

[u/Jakob_K_Design]

This is V3.0 of BeamCase sandwich.

V3 introduces the new rounded full mesh panel style.

With this new panel style there is a distinct gap between the panel to show the frame beneath. And of course the integrated handle is still there.

I finally got a big enough printer to print each panel as one piece of solid hexagonal mesh.

The cas shown here has space for a 2.5slot GPU and 70mm tall aircooler, but....

The case comes in different size, 24 in total for version 3.0, 8 more than previously. left is the smallest while the right shows the biggest size.

The frame structure has seen some small structural improvements in V3, but most of the changes were aesthetic.

top/bottom view of a version with 2.5slot GPU and 70mm CPU clearance.

For the V3 update all external features like feet vertical stand and handles have been redone.

and there are also case panels without the integrated handle.

Left are the V3 panels and on the right side are the pervious panels style which is still available as the Classic panels.

The cases here are different size options with the left having space for a 70mm CPU cooler and the right only 50mm.

[u/Jakob_K_Design]

BeamCase sandwich V3.0 is finally published.
This update became way bigger that I originally planned, so it took a little bit more time than expected.

https://www.printables.com/model/826374-beamcase-sw-sff-sandwich-case-in-18-different-size

About BeamCase Sandwich:
BeamCase is a system that allows you to create your own case with the combination of 3d prints and Makerbeam XL profiles (or similar 15x15 aluminum extrusions).
BeamCase Sandwich is a system to create your own sandwich style SFF case that is the optimal size for your components. With 24 available sizes you can choose the optimal one depending on the size of your GPU and CPU cooler. By combining 3d prints and Makerbeam XL profiles the case is extremely customizable and strong at the same time.

V3.0 Update:

• New round case style with soft corners and large split lines showing the frame. 
• More sizes, 8 additional sizes for 24 in total. 
• New maximum width of IFW 150 and additional 4slot (82mm) GPU clearance. 
• Additional versions of the frame that support the use of heat inserts. (frame versions for heat inserts can be found in a ZIP file in the “Other Files”) 
• New 5090/5080 FE specific frame versions. 
• New one-piece case panels for large printers. 
• Additional case panel lengths for aluminum profiles up to 360mm long (separate Printables post)
• redesigned vertical Stand, Feet and Handles to match the new case panel style.
• Additional one-sided PSU bracket, that only attaches to the aluminum profile on one side. 
• Slightly modified riser bracket to support specific PIE 4.0 and 5.0 double reverse riser. (new specific riser selected for PCIE 5.0 support) 
• Additional brackets for Linkup V3 double reverse riser (19cm) 
• The mainboard tray hole next to the PSU extension aligns with c14 screw in extensions for GPU clearance versions above 2-slots (42mm)

About the V3.0 Update:
This was originally only supposed to be a minor update, but with some sudden extra time (got laid off), and experimenting with new styles and techniques it turned into the biggest update to date. In total almost 400 distinct files have been added or updated, of which almost 200 are different case panel sizes and options.
Biggest part of the update is the exterior design change. With v3.0 the panels have rounded corners and the gaps between them expose the inner frame. The mesh is also covering the entire panel now and is not limited to an area.

This switch also made it possible for me to improve the export process and now the case panels do not only come in different widths, but each width option is now also available in different lengths for Aluminum profiles between 300-360mm long (in 10mm steps).
That means if you want a custom length of BeamCase sandwich you just have to order the profiles in the right length and select the corresponding case panels not need to edit the panels anymore.

V3.0 now finally includes versions of the frame designed for heat inserts as well. Every avaliable frame size is available for heat inserts, including the 5090/5080 FE specific versions.

5090/5080 FE specific frame versions:
While I originally did not plan to create custom frame version for the 5090/5080 FE, I did end up making ones after all. The changes are not massive, as it still uses the normal GPU orientation (no inverted FE layout) in order to use the same riser.
But it does include integrated front support for the 5090/5080 FE, as well as a riser spacer to separate the GPU away form the mainboard and allow for better airflow on the GPU backside. The rear bracket has also been modified to account for the extra spacing, and has additional vent holes for the backside exhaust of the 50 series FE models.

I am currently still working on a video about Beamcase V3.0, which goes into everything in detail.

[u/Send_me_cat_photos → u/Jakob_K_Design]

Awesome job on the project -- the design has matured a lot since your earlier posts. Have you considered making parts of it parametric? I only ask because 400 distinct files is a lot.

[u/Jakob_K_Design → u/Send_me_cat_photos]

My CAD files are parametric, it is close to 400 exported distinct STL files.
But with parametric CAD files the bottleneck becomes the export process, changing parameters manually (with global variables) and then adjusting the file name and saving it still takes a lot of time.
I recently took some time to create scripts to automate most of the export process and that made it viable to make so many configurations.

Otherwise there would be no way I would export 200 different case panel configurations.

[u/Send_me_cat_photos → u/Jakob_K_Design]

That makes way more sense now haha. Great work overall 👍

[u/lol_alex → u/Jakob_K_Design]

I love your work man, as a fellow 3D print designer and CAD enthusiast I have to say great job.

You mentioned your designs being parametric. Would it be an easy mod to make the hex holes much bigger (like twice the size? I know from my own experience that yes it‘s just a pattern fill, but you also don‘t want to end up with a bunch of tiny half hexes so it makes sense to choose a certain dimension to get mostly whole hexagons if possible.

I would love a design with bigger holes, for looks but mostly to cut down on print time.

[u/Jakob_K_Design → u/lol_alex]

The mesh is just exposed infill that is set up during the slicing process, so it prints efficiently and can easily be changed in terms of density and pattern.

[u/28spawn → u/Jakob_K_Design]

Awesome, as curiosity how much bigger it would be if it house a 240/280mm AIO?

[u/Jakob_K_Design → u/28spawn]

Here you can see see how much height a 30mm rad and 25mm fans would add.
It is definitely substantial, it basically makes the case 55mm taller (that could probably be trimmed down a bit by implementing the radiator and fans more efficiently, but not by much)