Parametric ATX Rackmount Server Chassis

The chassis supports ATX, Micro-ATX, and Mini-ITX motherboards, an SFX power supply, and two 120 mm fans.

The FreeCAD model is parametric in depth. The included configurations are designed around 14-inch and 16-inch rack depths, with all printed parts fitting within a 250 × 210 mm build area.

The chassis can also be extended significantly beyond 16 inches by changing the depth parameter in the FreeCAD model. At larger depths, some components may eventually exceed the 250 × 210 mm print area.

FEATURES:

• ATX, Micro-ATX, and Mini-ITX motherboard support

• SFX power supply support

• Mounting for 2 × 120 mm fans

• Adjustable chassis depth

• Segmented construction for printing on relatively small beds

• Base reinforced with steel rods across the printed joints

• Source FreeCAD model included

HARDWARE REQUIRED:

• 8 × 3 mm × 80 mm steel rods

• 33 × M3 × 20 mm screws

• 20 × M3 × 6 mm screws

• 53 × M3 nuts

• 10 × CNC Kitchen M3 heat-set inserts for the motherboard mounts

• 0–7 × CNC Kitchen M3 heat-set inserts for PCIe bracket mounts, depending on configuration

• 1 × 12 mm power button

CONSTRUCTION:

The chassis is divided into several printed sections.

The base sections are aligned and reinforced using eight 3 mm × 80 mm steel rods. These rods pass through aligned holes in the printed parts, helping locate the sections during assembly while adding rigidity across the joints.

The remaining components are fastened together with M3 hardware.

PRINTING:

The 14-inch and 16-inch configurations are designed so that every printed component fits within a 250 × 210 mm build area.

The prototype was printed using:

• PETG

• 15% gyroid infill

• 4 perimeters

• All parts are oriented flat against the build plate. Supports are required for some parts.

ADJUSTING THE DEPTH:

Chassis depth is controlled parametrically in the included FreeCAD model.

The provided configurations target 14-inch and 16-inch rack depths, but the chassis can be made considerably deeper if required.

There is much less room to reduce the depth below the current minimum because of the space required by the motherboard and other components.

After changing the depth parameter, check the resulting part dimensions and component clearances before printing.

ASSEMBLY:

The general assembly process is:

1. Print all chassis sections.

2. Install the motherboard heat-set inserts.

3. Align the base sections.

4. Insert the eight 3 mm × 80 mm steel rods through the base.

5. Fasten the printed sections together with the required M3 hardware.

6. Install any remaining heat-set inserts and chassis hardware.

7. Install the motherboard, SFX power supply, fans, and other server components.