Modular Open-Air PC Case|2020 Aluminum Extrusion

Build your own high-performance, open-air PC chassis using standard aluminum extrusions and 3D printed parts.

This design offers superior airflow for cooling, easy access to components for swapping hardware, and a rugged industrial look. It is designed to hold a standard Motherboard, PSU, AIO Liquid Cooler, and a vertical GPU.

Key Features:

• Maximum Airflow: Open design prevents heat buildup, perfect for gaming or overclocking.
• Modular: Based on 2020 aluminum profiles, so you can adjust the size to fit your needs.
• Robust: The combination of PLA/PETG and aluminum makes it extremely rigid.
• Vertical GPU Ready: Includes brackets to mount your graphics card separately (requires a riser cable).

Bill of Materials (BOM): To build this, you will need:

• 2020 Aluminum Extrusions: (2x350mm; 4x300mm; 2x250mm; 1x200mm)
• Screws: M4x6mm Screws (Socket Head recommended)
• Nuts: M4 T-Nuts (Hammer nuts or sliding nuts)
• PC Hardware: power button, PCIe Riser cable.

Assembly:

• Step A: Assemble 35 "Nut M4" parts by inserting a metal M4 hex nut into each printed housing.

Frame Assembly:

1. Step 1 (Side Frames): Take one 350mm profile (Vertical) and one 250mm profile (Base). Connect them using 4 "Nut M4" and 1 "Lateral Lock".

   1. Repeat this step 2 times to create the Left and Right side frames.

2. Step 2 (Main Structure): Connect the two side frames using the three 300mm profiles (Crossbars). Secure them using 16 "Nut M4" and 6 "L Lock" brackets.

   1. Before tightening: Slide 2 "Spacers MB 1" into each vertical bar (6 spacers total). Screw the brass motherboard standoffs into these spacers.
   2. Accessories: Screw the "Power Button" and "SSD Holder" onto the top part of the frame.
   3. Mounting: Install the Motherboard onto the brass standoffs.

3. Step 3 (GPU Base Sub-assembly): Connect one 300mm profile with one 200mm profile using 2 "Nut M4" and 1 "L Lock".

4. Step 4 (Final Frame Union): Attach the sub-assembly from Step 4 to the main frame using 4 "Nut M4" and 2 "L Lock". Ensure the three bars at the bottom are aligned.

5. Final Touches:

   1. Step 5: Install the "Fan Support" (for the radiator/fans) and the "GPU Support" (for the graphics card).

6. Step 6: Insert the End Caps into the exposed ends of the aluminum profiles for a clean look.

7. Step 7: Install all PC hardware components (PSU, GPU, Cabling, etc.).

Bonus: Cable Management I have included extra files in the download section specifically for cable management. These inserts fit into the aluminum profile slots and allow you to use standard zip ties to secure your cables. Use them to keep your build looking clean and professional!