SFF PC Feature Pack Case for Deskmini Motherboards

Introduction to this project:

It is a case replacement for the ASRock Deskmini series STX motherboards. I needed a powerful desktop processor and yet in a compact form factor. The original Deskmini case was too large for my liking and did not have sufficient cooling to run 105W TDP AMD CPUs. I have included features to improve its functional, servicability and cooling performance while reducing the volume to 1.5 litres.

I would strongly advise to only take up this DIY project if you have ample PC building experience as it is easy to physically damage components if you are not careful. In addition, due to the density of hardware in this chassis, it would be good to have god-tier cable management skills. (Crimping of fan wires and USB dupont connectors is not compulsory but helpful to manage the wiring)

Personally, I have built this for my travel use with the following hardware specifications:

• AMD Ryzen 7 9700X
• 2x48GB Crucial DDR5 5600MHz 
• 2TB Crucial T500 Gen4x4 NVMe SSD
• Intel AX210 (WiFi 6E+BT5.3)
• 230W Power Adapter (19V, 12.1A)

While I am basing this design off the X600 series, it will work for the X300 Deskmini as well. I cannot confirm it will work for the B660 (Intel version), though it should just be an offset of the CPU fan position in the worst case scenario.

This print should be doable on most printers as the largest item is only 165.40mm x 151mm on the print bed. I've also tried using PETG instead of ABS/ASA and it works well enough, you may print in PETG if your printer cannot reliably print in ABS/ASA.

Features:

• A powerful 12V 0.63A CPU Cooling Fan to handle 105W TDP AMD CPUs
• Active cooling for DRAM
• 1x Rear and 6x Side Exhaust Fans
• 4K In-built webcam
• PCIe 4.0x4 Oculink Port for eGPU connectivity or other Oculink devices
• An LCD display for stats monitoring and aesthetics
• In-built high gain WiFi antennas
• Handle for easy portability
• Allen Keys for on-the-go servicability
• Convenient CMOS reset (by inserting the 2mm allen key beside power button)

What to print (only takes 200-250g of filament!):

1. The .3mf file will contain all hard parts, the top panel should you not want to have our logo, a separate .stl file (Top Panel.stl) is also included in the files.
   • Print this using a 0.4mm nozzle or smaller, using a temperature resistant filament such as ABS or ASA. 
   • It is important to ensure you have calibrated your filament+printer beforehand to ensure dimensional accuracy. Any warping will also affect final assembly.
   • When printing the bottom panel in 0.20mm layer heights, add a pause before layer 29 (5.80mm) to insert 4 M2 nuts for the hinge feet.
2. One quantity of  "TPU Gasket for CPU Fan.stl"
   • Print this using a TPU95A or softer filament.

Items required for assembly

1. Essential Hardware Components
   • Compatible CPU, RAM, M.2 NVMe SSD (without heatsink), M.2 WiFi Card
2. Heatset Inserts
   • M2xOD3.2xL2 (8pcs)
   • M2xOD3.2xL4 (22pcs)
   • M3xOD4.2xL4 (10pcs)
   • Purchase Link
3. Screws & Nuts for Case
   • M2x3 Button Head Screws (4pcs)
     • Purchase Link
   • M2 Flat Head Countersunk Screws
     • Lengths: 6mm, 8mm, 12mm, 16mm, 20mm
       • Purchase Link
   • M3x45 Flat Head Countersunk Screws (4pcs)
     • Purchase Link
   • M3x8 Button Head Screws (6pcs)
     • Purchase Link
   • M2 Nut for Hinge Feet (4pcs), webcam (3pcs), rear fan (4pcs), CPU fan (4pcs) 
     • Purchase Link
4. CPU Cooler Heatsink
   • Thermalright AXP90-X47 Low Profile CPU Cooler
     • Purchase Link
   • 4x M3 Nylon Washers for mounting
     • Purchase Link
5. CPU Cooler Fan
   • 1x 92mm Nidec K07 DC12V Fan and 1x PWM Fan Adapter
     • Purchase Link
6. Rear Fan and DRAM Fans 
   • 2pcs of (25x25x10mm PWM) for DRAM
   • 1pcs of (30x30x10mm PWM) for Rear Panel
     • Purchase Link
7. Side Fans
   • 6pcs of (12V [45*45*10mm] 4 wire)
     • Purchase Link
8. Wifi Antenna
   • 2pcs of (Type E [12db 100*21mm])
     • Purchase Link
9. Oculink M.2 NVMe Adapter (20cm)
   • Purchase Link
10. 4K Webcam
    • Either AF (autofocus) or FF (fix focus) option
      • Purchase Link
11. M.2 NVMe SSD Heatsink
    • Copper 1
      • Purchase Link
12. RAM Heatsink
    • 1pcs 0.5mm and 1pcs 3.0mm per stick of RAM
      • Puchase Link
13. Carrying Handle
    • Design 635 - 128 Hole
      • Purchase Link
14. 5" USB C IPS LCD Display
    • Kit 1 or whichever is cheapest
      • Purchase Link
15. Allen Key
    • 1.5mm and 2.0mm
      • Purchase Link
16. Silicone Feet
    • Purchase Link
17. Power Button
    • Self-Reset, 3-9V, 12mm Opening
      • Purchase Link
18. Motherboard IO adapter
    • Small 8 Pin
      • Purchase Link
19. Magnets
    • Round Magnet 8x1mm (10pcs) 
      • Purchase Link
    • Round Magnet 4x2mm (4pcs)
      • Purchase Link
    • Rectangle Magnet 15x6x3mm (1pcs)
      • Purchase Link
    • Rectangle Magnet 10x5x2mm (1pcs)
      • Purchase Link
20. [Optional] 230W 19V Power Supply (Only for PPT >90W CPU)
    • Purchase Link
21. [Optional] Kapton Tape
    • Apply on back of motherboard around cooler mounting holes
    • Fully cover the LCD Display back cover preventing direct contact with back of motherboard
    • Between the side exhaust fans and the motherboard
    • On the Oculink Connector before mounting the motherboard
      • Purchase Link

Preparation 1 (Heatset Inserts)

Blue: M2xOD3.2xL4 (22 needed)

Green: M2xOD3.2xL2 (8 needed)

Red: M3xOD4.2xL4 (10 needed)

Preparation 2 (Magnets)

Inner face of Bottom Panel: Glue rectangle magnets here

Outside face of Bottom Panel: Glue a total of 4 Magnets

Hinge Feet: 1 for each feet

RAM Fan Cover: 1 on each side

Top Panel and Exhaust Grills: 4 in total

Assembly Guide:

(sorry for the lack of pictures, I am lazy. this will also be brief as it assumes you already have the knowledge required for PC assembly)

1. Disassemble the 5" LCD display to reveal only the barebone components (Screen/Ribbon Cable/PCB/USB Internal Header Cable). Place this into the top panel and secure the screen in place using the screen back cover.
2. Install the following components onto the motherboard:
   • CPU, RAM+Heatsink, WiFi Card without antenna, M.2 Oculink Card on back of motherboard
   • Heatsink from AXP90-X47 (AM5 users may need to remove the stock retention mechanism+backplate and secure with M3 washers and included nut with cooler)
3. Secure the Oculink port to the printed top panel with 2pcs M3x8 screws, followed by the motherboard with 4pcs M3x8 screws.
4. Install the exhaust grill covers into the slots of the top panel, taking note of the correct orientation
5. Prepare the rear panel by installing the 30x10mm fan using 4pcs M2x16 screws, and secure it to the top panel using 3pcs M2x8 screws
6. Prepare the side panels by doing the following:
   • Screw on the handle into the 2 prints (Side Panel Handle F and Side Panel Handle R)
     • Then secure this onto the side panel (top) using 4pcs of M2x6 and the 2pcs of screws included with the handle
   • Stick both WiFi antennas into the cutout provided on the side panels
   • Cut silicone feet strip and stick into the cutout provided on the side panels
   • Orientate the 6 blower exhaust fans and push them into the pegs, secure them in place using cable ties (optional: crimp the PWM connectors for an easier time with cable management later)
7. Install both of the side panels to the bottom panel using 4pcs of M2x8 screws
8. Fix the antenna connectors onto the M.2 WiFi card and then install the M.2 NVMe SSD + heatsink
9. Prepare the front panel by doing the following:
   • Install the Power button
   • Install the webcam using 3pcs M2 screws and M2 nuts, the USB connector should be closer to the long side of the panel
10. Connect the following wires to the motherboard:
    • USB header from 5" LCD display and webcam
    • Power button switch and light using the small IO adapter
11. Secure the front panel to the bottom panel using 3pcs M2x8 screws
12. Prepare the top panel by doing the following:
    • Place the TPU gasket in position, install the 92mm CPU cooler fan using 4pcs M2x3 screws and M2 nuts, connect the PWM adapter for the fan (note the orientation, a cutout has been made for the ribbon cable in the top panel as well)
    • Install the two 25mm RAM fans using 8pcs M2x12 screws and place the printed RAM fan cover in position
    • Using the silicone feet strip, cut small lengths for the 4 hinge feet. Magnetically attach the 4 hinge feet in the top panel
    • Place both allen keys in the cutouts provided
    • Install the CPU Fan Frame over the 92mm CPU fan, check that the fan does not hit this frame
13. Connect all fans to the 2 fan headers on the motherboard
    • Each fan header supports up to a maximum of 1.5A. I suggest to connect the 6 exhaust fans to header 2 and the CPU+Rear+RAM fans to header 1. 
    • (This will be a test of your cable management skills. If not done properly, the rear fan or exhaust fans may be affected)
14. Lastly assemble the remaining top panel using: 
    • 4pcs M3x45mm screws at the corners.
    • 4pcs M2x20mm screws through each of the 4 hinge feet
    • 2pcs M2x8mm screws to the rear and front panel between the hinge feet points
    • 6pcs M2x8mm screws to the side panels

Your finished product should look the same as my images, if any parts do not fit, check your printer's dimensional accuracy with the filament you used and apply an appropiate glue to prevent warping.

BIOS Instructions/Reminders:

• Update to latest BIOS on official website to allow the following features:
  • 180W Power Adapter mode
  • Unlock ability to tune Curve Optimizer and Curve Shaper (CO/CS)
  • ECO Mode 105W
  • PPT, TDC, EDC settings for pushing higher power draw
  • (In ASRock BIOS there are 2 pages for PPT,  TDC, EDC. Both pages should be changed for power limits to take effect)
  • RAM overclocking (increase speed, adjust timings)
• Tune your fan curves to your desired speed/noise level as the CPU fan can be loud on default mode
• Ensure thermal limits are set in BIOS to prevent CPU overheating
• For higher TDP CPUs, it is recommended to undervolt using PBO (CS/CO) to improve performance and prevent thermal throttling

My Sharings Post-Assembly:

• When using with an AM5 CPU, since the stock retention mechanism and backplate needs to be removed, it is advisable to use a very sticky thermal material (I use PTM7950) so the CPU is stuck better to the heatsink of the cooler and will not fall onto the socket pins
• Managed to reach 140W long duration power draw on my AMD R7 9700X in this set up
  • 30min Sustained PPT/Temps at 100% RPM
    • 140W @ 99°C
    • 100W @ 85°C
• 2x48GB Crucial DDR5 has been overclocked to 6000C32 @ 1.45V and peak temps are at <60°C
• Smooth gameplay using an RX 7800XT external GPU
• Easy BIOS tuning as CMOS reset is as easy as inserting the 2mm allen key into the slot  beside the power button
• Brought this to a few different counties in Asia so far with 0 issues at all. They just treated this similar to a laptop since it was just a PC with a screen to them
• Use this with a foldable bluetooth keyboard and mouse for traveling so all USB ports can be freed up for other purposes
• It might be possible to squeeze in a SATA docking port on it as well, though this will require even more technical knowledge to convert the existing Deskmini SATA adapters

Additional Comments:

• This has taken me a long time to prototype and bring to life. This model is free to download as I believe the SFF PC community will enjoy this as much as I have.
• I also do think it would be great if it inspires others to jam-pack their Deskminis with features!
• Please reach out to me if you wish to share this model publicly, I would love to follow. <3