Orange Pi 5 Desktop Case V2

Update - I don't like the access to the SBC in this case, please see my profile for the Orange Pi 5 Desktop Case Version Tres (see the 3mf file without the fan) or use this link:

https://www.printables.com/model/628109-orange-pi-5-desktop-case-version-tres

The fan standoff included in this model is still useful.

→ original description is below

My original design worked great and could be printed without supports.  The only thing I didn't like about it was that it had a sort of “chonky boi” aesthetic.  It is stable, short enough to not block my screen but still tall enough that my thick HDMI cable could bend up into it without stressing the OPi.  The ports that I need access to are easy to get to.  The case protects the OPi from me and the cat.

So I went back to Fusion 360 and tried for a more svelte silhouette.  Since the dimensions are fixed by the OPi itself and the HDMI cable radius, the changes are cosmetic.  But I do think it looks a little better.  Unfortunately the top needs to be printed right side up, with grid supports.  The supports were easy to remove.  

To get the sides to print reliably using PrusaSlicer I selected Print Settings/"Layers and Perimeters" “Extra perimeters on overhangs (Experimental)” and “Avoid crossing curled overhangs (Experimental)”.  I used 3 perimeters, 3 top layers and 3 bottom layers with 30% gyroid infill.  I made some minor changes after printing my case, particularly around the microSD slot, to improve the printing. 

I did some testing on the thermal pads with the heat sink.  I replaced the original pads with Gelid Solutions GP-Ultimate, 3 mm thick, single piece 120mmx20mm and the attached graph shows the results.   Obviously the thermal pads make a huge difference with a temperature difference prior to throttling of 10 C for the new pads no fan and 18 C for the new pads with fan.  Ambient temperature was 17.3 C,

Here is the script for my test-

Here is the script I used for my test-

#!/usr/bin/env bash
## script to display seconds and cpu temperature
## to send to file $ ./test.sh | tee temp.log
## run the following for stress test
## stress -t 60 --cpu 8
##
## to run both at same time
## stress -t 1200 --cpu 8 &./test.sh | tee temp.log
##
## to monitor cpu speed
## armbianmonitor -m
start=$(date +"%s")
while :
do
now=$(date +"%s")
temp=$(cat /etc/armbianmonitor/datasources/soctemp)
echo $(($now-$start)) $temp
sleep 1
done
 

Update September 6, 2023: The fan started making noise, so I bought a new fan.  It came with M2.5 x 14 screws. I had seen posts about the fan being backwards as shown in the manufacturers photos of this heat sink, so I check and sure enough it was.  And the fan is too close anyway.  So I made a standoff and used the new screws, and mounted the fan to blow onto the heat sink. I connected all 4 standoffs so that it would print without supports and was easier to install. I will post another update if/when I redo the benchmark.