Orange/Raspberry Pi Zero 2W Snap-Fit Case Offsite Storate

Purpose

I have many backups at home, but I don't have any offsite backups, which are essential for essential document files. I wanted to create some sort of low-power server and leave it at my parent's place.

Why So Big?

This case is larger than you would expect for an Orange Pi Zero 2W (same form factor as the Raspberry Pi Zero 2W). The main reason for the enlarged size is self containment. Here are other factors in order of importance:

1. When you connect Dupont connectors to the GPIO, you need overhead clearance.
2. This box needs to be self-contained. It will be connected to an outlet and forgotten at my parent's place. It provides room for a USB thumb drive (maximum 25 mm in length from the PCB to the end of the drive), as well as room for an LED to display the power status of the device, as well as a Power On/Off button. There is a Wi-Fi antenna as well.
3. Heatsinks. During a compile process, I got this thing up to ~86C, you need to cool it for the occasional hard computes.

Features

• Snap fit case.
• Lips for easy disassembly.
• Close the case with bolts and heatset inserts (optional).
• Power status indicator (LED 5 mm).
• Power button.
• Power USB cable hole for either USB port (Note, in my testing, a USB drive is not readable if connected to the first USB port).
• TPU plug for unused USB cable hole.
• Holes for airflow.

Bill of Materials

• 4 x SHCS M3x L16mm (Optional)
• 4 x Heatset inserts M3 D4.6mm (Optional)
• 1 x 5mm LED
• 1 x Momentary power button

Behaviour

1. The button blinks while pressed.
2. After 3 seconds (adjustable), the OPi will shutdown.
3. The light turns off.

Print Settings

• Print all parts without supports, except for the bottom piece (it needs supports for the bolt head holes).
• Print parts are oriented.

Code For Button and LED Functionality

Find the code on my repo here.

Notes

• When snapping the case together, make sure you go around all the edges and squeeze the 2 halves together.
• I'm using restic for encrypted backups. My 40GB worth of essential data is being compressed down to ~19GB.
• I'm using this USB drive. I had to cut one side (it's plastic) with some snips.
• The LED is a press fit. If you have trouble getting it in, just sand the hole down a bit.

Models Used During Development

• LED
• microSD
• Header Pins
• Orange Pi Zero 2W
• Momentary Push Button Switch
• SHCS

Buy me a Ko-fi. 😀