MackRack: A Customizable 10-Inch Server Rack Solution

MackRack: A Customizable 10-Inch Server Rack Solution

The MackRack is a modular 10-inch rack designed for 3D printing and assembly with 2020 aluminum extrusion. This rack is multiboard-compatible (see multiboard.io for add-on ideas) and adaptable to various sizes (4U, 6U, 8U, or custom). While it’s designed to align with other 10-inch rack standards, the 2020 extrusion creates a slightly larger gap (222mm between rails, 242mm screw-to-screw across). Measure carefully if combining with other rack designs. Customize and remix freely—please share your adaptations with the community for free use!

Step 1: Choose Your Rack Size
Select your desired height:
• 4U: Compact option
• 6U: Mid-size
• 8U: Larger capacity
• Custom: Adjust lengths as needed

Step 2: Materials & Tools
• 3D Printing Filament: PLA may work, but PETG is recommended for heat resistance.
• Aluminum: 2020 extrusion (length depends on size, see cuts below).
• Hardware:
○ M3 x 6mm screws (quantity varies; for faceplates; M3 thumbscrews are a stylish alternative)
○ 48 M3 x 8mm screws (for corner attachments)
○ 4 M3 x 20mm screws (with washers, for handles)
○ M3 washers (32 minimum; adjust based on faceplate setup)
• Tools: 3D printer, saw for cutting aluminum, screwdriver or hex key.

Step 3: Cut the 2020 Aluminum Extrusion
Cut your aluminum to size based on your chosen rack height:
• Vertical (4 pieces):
○ 4U: 218mm
○ 6U: 307mm
○ 8U: 396mm
○ 10U: 485mm
• Horizontal Face (4 pieces): 210mm
• Horizontal Side (4 pieces): 170mm
• Total Length:
○ 4U: 2392mm
○ 6U: 2848mm
○ 8U: 3304mm
○ 10U: 3760mm

Step 4: Print the Parts
Below are the 3D-printed components, with recommended print settings. All parts use 2-3 walls, 15-25% infill, and no supports unless noted.
1. MackRack Corner
○ Quantity: 8
○ Orientation: Angled on the flat corner
○ Walls: 3
○ Infill: 15%
2. MackRack T-Slot Corner
○ Quantity: 48
○ Orientation: Flat side down (angled edges down)
○ Walls: 2
○ Infill: 15%
3. MackRack T-Slot 1U
○ Quantity:
§ 4U: 18 (minimum)
§ 6U: 24 (minimum)
§ 8U: 32 (minimum)
○ Orientation: Flat side down (angled edges down)
○ Walls: 2
○ Infill: 15%
○ Note: Print extra for optional add-ons on other slot faces.
4. MackRack T-Slot Nut
○ Quantity: Optional (for customizations)
○ Orientation: Flat side down (angled edges down)
○ Walls: 2
○ Infill: 15%
5. MackRack Upper & Lower Panels
○ Quantity: 2
○ Orientation: Flat side down
○ Walls: 2
○ Infill: 15%
○ Note: Multiboard-compatible.
6. MackRack Side Panel
○ Quantity: 2
○ Size: Choose 4U, 6U, 8U, or 10U version
○ Orientation: Flat side down
○ Walls: 2
○ Infill: 15%
○ Note: If too large for your print bed, split in your slicer and reconnect with quad multiboard snaps. Use single multiboard snaps for decoration on smaller panels. Multiboard-compatible.
7. M3 Washers
○ Quantity: 32 (adjust based on faceplate needs)
○ Orientation: Flat side down
○ Walls: 2
○ Infill: 15%
8. MackRack Side Handles or MackRack-CrossHandle
○ Quantity: 2 or 1
○ Orientation: Flat side down
○ Walls: 3
○ Infill: 25%

Step 5: Assembly
Review the photos for guidance and make sure to add the t-slot corner attachments, panels, and 1u t-slots as you go where you want them.

Customization Tips
• Explore multiboard.io for compatible add-ons (e.g., shelves, cable management).
• Remix the design for unique sizes or features—just share your work back with the community!
• Verify compatibility with other 10-inch racks by measuring the 222mm rail gap and 242mm screw spacing.

Final Notes
This design balances accessibility, durability, and flexibility. PETG is recommended for heat-prone environments (e.g., server rooms). Share your builds, mods, and feedback—let’s grow this project together!

04/08/25 Update: Added the Cross handle for a single handle option. Note that if you have adjusted the width of the rack you'll need to scale this handle to match. Also added some more photos of assembly process.

04/14/25 Update: Uploaded a 2U Raspberry Pi Frame and caddys that work with MackRack. Find them and other compatible accessories in this collection - https://www.thingiverse.com/_jeramy/collections/43170961/things