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Custom PC Case

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Wayne Toh

Project Timeline

Sep 2025 - Current

OVERVIEW

This project focuses on designing and fabricating a fully custom PC case that balances functionality, aesthetics, and efficient thermal management. The goal is to create a modular and visually appealing enclosure that supports high-performance hardware while maintaining optimal airflow and ease of assembly. The design incorporates precision sheet metal fabrication, cable management channels, and strategic fan placements for enhanced cooling performance.

HighlightS

Will design a modular enclosure supporting both ATX and micro-ATX configurations.

Will improve internal airflow efficiency through optimized fan and vent placement using CFD.

Will integrate custom cable management channels for cleaner internal layout and ensure load placement is optimal using FEA.

Will apply sheet metal bending and laser-cutting processes for precision fabrication.

SKILLS

CADFEASheetmetal DFMCFD

Additional Details

As someone who loves building PC, I want to integrate the skills I have absorbed at Foxconn as well as the current CAD modeling and simulation skills I am learning by creating my own custom PC case, with built in anti-GPU sag and custom cable management. I am currently looking into design ideas and the project is ongoing.

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The custom PC case project will be developed using SolidWorks for 3D modeling and assembly design, enabling precise control over component spacing, airflow channels, and aesthetic proportions. The structure will be fabricated primarily from aluminum sheet metal for its balance of strength, weight, and machinability, with selective use of acrylic panels for visual access to internal components.

Key design considerations will include thermal management, vibration isolation, and ease of maintenance, ensuring that both performance and usability are prioritized. The case will feature modular mounting brackets, removable side panels, and tool-less assembly mechanisms to simplify upgrades and maintenance. Once the CAD model is finalized, fabrication will hopefully proceed through CNC laser cutting, sheet metal bending, and powder coating for a professional finish.

To validate performance, thermal and airflow simulations will be conducted to compare design iterations, followed by prototype assembly and real-world testing with standard PC components.

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