Raspberry Pi 5 Case - small modifications for easier assembly

About:

This is a slight modification of the excellent design by StealthNode.  I made additions and changes to make it easier for me to assemble and to connect the USB-C and HDMI plugs.  StealthNode has a Thin Side IO Cover that accomplishes the same thing regarding the USB-C and HDMI plugs.  I wanted to keep the same thickness of the original IO Cover and try only removing just enough material to make it work.  I changed the bottom half to trap the nuts inside it by pausing the print job to insert the nuts.  That arrangement makes assembly easier for me.  I made two varieties of the bottom.  There is one bottom for hex nuts and one for square nuts.  I also changed the bottom by removing a small amount a material near the 2nd HDMI port to make inserting the HDMI plug easier.  Everything else is the same.  There is a Power Button in the back as in StealthNode's.  The two parts of the case snap together and you can release them by pushing in the front sides and lifting up.  I made my modifications using SolidWorks.  I printed everything with a 0.4mm nozzle.  I used PLA and printed this with 1mm perimeters (top, bottom and sides).  No supports needed.

You will need:

• 4 x M2.5 screws and 4 x M2.5 nuts (hex or square)
• 1 Raspberry Pi 5
• Optional heatsink & fan

Both versions have the nuts below in the bottom half with the screw coming in from the top to mount the RPi5 to the bottom half.  It's necessary to pause the print job to insert the nuts into their places and then continue the printing.  I've included 3MF files that have the pause in the correct place for you.  The Power Button is a separate 3MF file so you can print it in clear filament if you want.

Assembly

1. Before starting, remove the SD card from the RPi.
2. Insert the power button to the case
3. Line up the side IO cover with the IO slot on the RPi and insert making sure the power and HDMI ports are on the bottom
4. Then insert the RPi into the bottom half of the case ensuring that the IO cover slots into place.
5. Add screws where necessary to hold the RPi in place.
6. If using HATs or DSI cables attach them now.
7. Line up the back clip of the top half with the slot in the bottom half and insert.
8. Apply some pressure downwards to the front and push inwards the sides on the marked points, the top piece should clip into place.
9. To remove the top piece, push inwards on marked parts on the sides of the top piece and pull upwards.