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An updated version for this has been released. Please find it here.

Background

These are stackable Raspberry Pi 2 & 3 cases for parallel programming and clusters. The idea is that the cases can be used individually for small Pi projects or scaled to as many as needed with modules that can aid in larger configurations.

Modules

• Covered: Fully enclosed Pi case. This is a case focused on aesthetics, but still has plenty of vents for proper cooling. More material is used, but the Pi will also be better protected.
• Slim: Minimal Pi case design. This will use less material, but leaves the Pi less protected. Better cooling is a perk of this design.
• 120mm Fan: For those who need extra cooling, the fan will suck ambient air in to the stack. It is recommended with this setup to use a fan guard (link at bottom of description) as well as position the 30mm Pi fans to suck air out of each case.
• POE Hat: Power over Ethernet will make the wiring for this setup much easier. Please use case covers titled R-Pi POE Case Cover.stl or Slim - R-Pi POE Case Cover.stl to use this module. Also note that the "standoff" version of the base must be used.
• New modules will be coming soon (Ethernet Switch, Power Supply).

Each case is held together by M3x12mm male-female standoffs. The stacking is done by pegs that press in tightly to ensure there is no movement among each module. Both types of cases are the same dimensions, so there is no problem with mixing them up in a stack. For each type of case, there is an option for a base that uses standoffs or pegs to attach the Pi. If you are using the standoff version, you do not need standoffs to attach the Pi, only 4X M2.5x5mm Screws and 4X M2.5 Nuts. Then, if you are using a hat, you can directly attach the male-ends of the standoffs on the base. The pegs are a great option for those who do not have M2.5 standoffs on hand and when not using hats.

For all cases, run a 5V 30mm fan (link at bottom of description) connected to a power pin on the Pi. This fan should be sucking the hot air inside the case to ambient.

Required Hardware

• Individual Case (same for Slim as for Covered)
  • 1X R-Pi Case Cover.stl (Slim or Covered configuration). To use the POE hat with your Raspberry Pi, please use the covers titled R-Pi POE Case Cover.stl or Slim - R-Pi POE Case Cover.stl
  • 1X R-Pi Case Base.stl (Slim or Covered configuration). For use with the POE hat, use the "standoff" version of the base files.
  • 4X M3x12mm Male-Female Standoffs
  • 4X M3x14mm Phillips Head Screws (for fan)
  • 8X M3 Nuts (for standoffs and fan)
  • 4X M3x5mm Phillips Head Screws (for standoffs)
  • 1X 5V Raspberry Pi Fan
• Double Stack
  • 2X Hardware from "Individual" parts list
  • 4X Triple Stack Standoffs.stl or 4X Quad Stack Standoffs.stl
• Triple Stack with 120mm Fan
  • 3X Hardware from "Individual" parts list
  • 2X Fan Platform.stl
  • 2X 120mm Fan L-Bracket (this can also be the 16mm one. Please measure the distance between the flanges before printing. They are usually 19mm or 16mm. If your size is not either of these, please let me know!)
  • 16X Triple Stack Standoffs.stl
  • 4X M4 Nuts (for large fan)
  • 4X M4x30mm Screw (for large fan)
  • 4X M3 Nuts (for mounting fan)
  • 4X M3x12mm (for mounting fan)
  • 1X 120mm fan
  • 1X 120mm fan guard (highly recommended)
• Quad Stack with 120mm Fan
  • 4X Hardware from "Individual" parts list
  • 2X Fan Platform.stl
  • 2X Slim - Fan Block Spacer.stl
  • 2X 120mm Fan L-Bracket (this can also be the 16mm one. Please measure the distance between the flanges before printing. They are usually 19mm or 16mm. If your size is not either of these, please let me know!)
  • 20X Quad Stack Standoffs.stl
  • 4X M4 Nuts (for large fan)
  • 4X M4x30mm Screw (for large fan)
  • 4X M3 Nuts (for mounting fan)
  • 4X M3x20mm (for mounting fan)
  • 1X 120mm fan
  • 1X 120mm fan guard (highly recommended)

If you plan on linking stacks together, substitute the fan mounting screws for M3x25mm and M3x40mm on the triple and quad stack, respectively. Also, if you plan on linking a 3/4 stack together, use M3x35mm for the fan mounting screws.

Recommended Print Settings

• Use supports on each print (touching build plate)
• Layer resolution <= 0.2mm

Helpful Links

Fan guard link:
https://www.thingiverse.com/thing:2802474
For this model, I used a fan grill from GradCAD by Igor Erokhin:
https://grabcad.com/library/120mm-fan-grill-1

5V Pi fans:
https://www.amazon.com/Easycargo-Raspberry-30x30x7mm-Brushless-30mmx30mmx7mm/dp/B0792BW2VH/ref=sr_1_8?ie=UTF8&qid=1547336001&sr=8-8&keywords=raspberry+pi+fan

A step file is available of the fan platform and the fan bracket for those who would like to create their own modules and/or adjustments. Please share these with me and I will link them to this page!

Please comment with any questions or recommendations you may have!

Special Thanks & Tip

I am very passionate about the open-source community that provides a means for anyone to make, create, and remix amazing files across the web. It is truly amazing what additive manufacturing has accomplished by delivering a fast and affordable means to manufacture parts. Better yet, the bright and driven community behind the tech makes it even easier for those interested to get involved! Each of my designs are made free of capital but my own. If you found this particular project useful, please consider leaving me a tip (you don't have to, but if you insist, a small donation would be greatly appreciated!). This will go towards funding future projects like these, so I can continue to share my designs with the community!