Variable Voltage ATX Power Supply

Custom built variable voltage ATX power supply.  Variable 0-50v and dedicated 5v and 3.3v outputs.  USB charger.

Case is held together with M3 10mm socket head  screws and heat inserts.  I used 3mm and 5mm inserts.  Fan required a longer M3 screw - not sure what size.  

Boost module sits on the bottom of the case with the heatsink side facing up towards the fan.  There are standoffs with plenty of clearance below the components on the module.

I used 16 awg wire as this was the smallest i had.  If I were to redo this, I'd probably change to 20awg for most of the powered components that needed extra wire.

I installed the components in the face plate and soldered the connections before mounting to the rest of the frame.  Front and rear face plates hold the top and bottom in place.  Side panels mount to face and rear plates.  Its not that elegant when putting together, but it looks good when completed!

The PSU board and ATX breakout boards are mounted to the right panel using the 5mm standoffs.  The outside of the case has nut retainers that should hold the M3 nuts.  A few of them required heat to get into place.  I would've redesigned the panel but I didn't want to reprint for just this.

The fan that comes with the PSU is a 2 pin fan.  I wanted to use upgraded fans I had on hand.  They were 4 pin.  I used a PWM fan splitter and Dupont connectors from an Arduino kit to adapt to the PSU fan connector.  The holes for the top fan don't line up too well, but the top grille snaps into place with no movement and holds the fan in place.  There is no noise or wobble from the fan not being screwed in place.  Side fan is held in place with a long M3 screw and nut.  

Rear power switch and plug had to be de-soldered from the wires to mount in the rear plate.  There is also 120/220v switch that i just covered in electrical tape and tucked into the case.  I was not sure how to remove it.  

Bottom feet I intend to print in TPU…I haven't printed TPU with this new printer yet.  Case sits stable without them.  I just thought it would look nice.

I printed the case in PETG.  

BOM:

Amp meters

https://www.amazon.com/dp/B0CQC6781P?ref=ppx_yo2ov_dt_b_fed_asin_title

USB Charger:

https://www.amazon.com/dp/B0BNJ2DMTP?ref=ppx_yo2ov_dt_b_fed_asin_title

Voltage Boost:

https://www.amazon.com/dp/B07T137H2Y?ref=ppx_yo2ov_dt_b_fed_asin_title

Banana jacks:

https://www.amazon.com/dp/B093W45Y6X?psc=1&ref=ppx_yo2ov_dt_b_product_details

ATX Breakout Board

https://www.amazon.com/dp/B09QX2LYPN?psc=1&ref=ppx_yo2ov_dt_b_product_details

Banana Leads

https://www.amazon.com/dp/B07NWXR4GJ?psc=1&ref=ppx_yo2ov_dt_b_product_details

Fuse Holders:

https://www.amazon.com/dp/B08JHM2DQY?psc=1&ref=ppx_yo2ov_dt_b_product_details

Power Switch:

https://www.amazon.com/dp/B09TPBC8KX?psc=1&ref=ppx_yo2ov_dt_b_product_details

PSU:

https://www.amazon.com/dp/B0CZRMY588?ref=ppx_yo2ov_dt_b_fed_asin_title

Buck Converter:

https://www.amazon.com/dp/B01FNVESV2?ref=ppx_yo2ov_dt_b_fed_asin_title

Side fan is a 120mm Corsair fan I had laying around, but the PSU comes with a fan and the mounting points are the same.  Top fan is a 92mm fan that I believe is this one (i had it laying around and forget what it was exactly):

https://www.amazon.com/gp/product/B07ZP6KKKZ/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1