Corsair 6500D HSW front panel

Turn the Corsair 6500D front exhaust panel in a HSW. No alterations to the case are required, HSW is attached with gravity and magnets.

Note on airflow impact

Obstructing air intake or exhaust of a PC case is never a great idea, so before covering the front panel with this, make sure you have adequate, alternate airflow. If the front panel is used as fan exhaust, you may want to measure the temperature of expelled air under prolonged load and adjust print material to one that can withstand prolonged exposure. 

There is also a few centimeters of coverage over the top panel but airflow for any top fans should not be restricted in any significant way by this model.

Print settings

PLA should be fine but that will depend on how fans are configured an how hot the expelled air is. Printing the model in PLA should make the fit snug, if you print in another material, print a test slice first and accommodate for any expansion or shrinkage.

• PLA: consider temps for front exhaust fan configurations

• nozzle: 0.4mm

• layer height, 0.15mm, though 0.2 should be fine I suppose

• infill: 15% (gyroid)

• supports: none. But I do recommend doing a test print with a slice of the top panel to ensure you have clean support-less bridges.

Bill of materials

• 16 magnets 10mm diameter x 3mm thickness

• 38 magnets 6mm diameters x 3mm thickness

  • Optionally 2 additional 6x3mm magnets  for the tray

• glue to affix magnets to print material

Do you really need all those magnets? Probably not, I tend to err on the side of caution and it's not like these cost a fortune.

Print & assembly

First and foremost I suggest to create some smaller test slices of the model to make sure the magnets fit as expected and the printed model fits the case as expected. I have no reason to think there may be variances in the case, but I can't be certain there's no minor changes to the case or your print that could be an issue to make things fit. Measure twice, print once.

Import the model to your slices and split into objects, there is a split halfway the front panel to ensure the model fits a (300x300mm) print bed with ease. For smaller print beds I have no STLs available, if needed you could alter the OpenSCAD design to add additional splits, see below.

I opted to have the magnets exposed to make a stronger connection with the case, I do recommend to place some masking or other tape to the case where the magnets interface with the case to avoid any coloration or reaction to the glue holding the magnets. Ask me how I know...

I only used glue to keep magnets in place, the bottom HSW part stays in place nicely with just magnets. Consider using non-single inserts to further combine both parts.

Magnet polarity should not really matter but you might just as well try to be consistent or use the polarity that ensures the best result.

Attachments and extras

In addition to the front panel HSW, some additional files are available.

• Use the top of the front panel as Steam Deck stand.

• Add a drawer under the case / front panel.

OpenSCAD

• Requires HSW lib and BOSL2, see here for detail.

Changelog

• 2026-04-10: added tray and Steam Deck stand

• 2026-04-06: initial version