Raspberry Pi 1U Rack Mount (19” & 10”) - Press-Fit System - PoE ONLY

This is a 1U remix of my Raspberry Pi 2U Rack Mount and russross's 1U original design (https://www.thingiverse.com/thing:4125055 or https://www.printables.com/model/458627-raspberry-pi-4-1u-rackmount-bracket).

The front and rear rail design eliminates the original Pi frame - saving time and filament. While the original designs utilized threaded rods for structural integrity, this 1U version introduces a streamlined modular assembly that eliminates the need for extra hardware.

The core change in this remix is the introduction of 4 square connector pins that are press-fitted directly between the modular pieces. This creates a friction-locked assembly that is perfectly suited for the slimmer 1U profile. (You will notice that a slight modification has been made to the design since the photos were taken - the upper pins now extend through the upper rails for a little added stability.)

NOTE: This is for PoE applications ONLY.

Compatibility & Fit

• Standard 19" Racks: Designed at 440mm (17.3") wide to fit the standard 450.85mm (17.75") internal clearance.

• Mini 10" Racks: Designed at 216mm (8.5") wide to fit the standard 222.25mm (8.75") internal clearance.

• Verification: Before printing, please verify your rail-to-rail distance. This design provides a ~5mm buffer to ensure a smooth fit even with minor rail variances or filament expansion.

• Tray System: The original design’s Pi tray is still used (it is included for your convenience).

Assembly Tips

1. The Connector Fit Test (Highly Recommended)

Before committing to the full rack print, print a Connector Pin and use the included Connector Fit Test model.

• The Goal: A firm "transition fit" where the pin can be pushed in by hand or seated with light taps.

• Tolerances: The internal holes are 7.0mm x 7.0mm, and the pins are 6.8mm x 6.8mm.

• Adjusting Fit: If the test is too loose or too tight, scale the width (X and Y) of the pin in your slicer by 1–2%. Do not change the length (Z) of the pin, as this will affect the overall rack alignment.

2. Printing for Maximum Strength

• Connector Pins: These MUST be printed horizontally (laying flat on the bed). This ensures the layer lines run the length of the pin, providing maximum shear strength. Use 100% solid infill.

• Main Rails/Ears: Use a minimum of 4 perimeters/walls. This provides the necessary rigidity for the 19" or 10" span and ensures the ear mounting holes won't crack under screw tension.

• Z-Seam Tip: For the cleanest fit, set your Z-seam to one of the corners of the square pins. This prevents a "seam-bulge" on the flat faces that could interfere with the press-fit.

• Material: PLA will work. However, PETG, PETG-CF or ASA is recommended for structural strength and heat resistance.

3. Final Assembly

• Seating the Pins: If the fit is tight, use a small hammer or the butt of a screwdriver to gently tap the connectors into the rails.

• Squaring the Frame: Assemble the rack on a flat surface. Ensure all segments are fully seated and square.

• Optional Permanent Bond: While the friction fit is designed to be sufficient for standard use, I chose to use superglue and lightly clamp the assembly to permanently connect the pieces.