Embrace Innovation: The Ultimate Compact 3D Printed Raspberry Pi 5 Case
The Raspberry Pi 5 revolutionizes single-board computing with its enhanced processing power, dual HDMI outputs, and PCIe connectivity. However, with great power comes huge thermal management requirements and vulnerability. For intensive industrial applications, off-the-shelf plastic enclosures often fall short in terms of cooling efficiency and durability. This is where modern additive manufacturing comes into play. Enter Compact 3D printed housing— Not just a protective case, but also a powerful heat dissipation and EMI-resistant power supply specially tailored for Pi 5.
Why choose 3D printing instead of traditional cases?
Traditional enclosures prioritize low cost over adaptability. Plastic injection molding limits design innovation, especially the internal airflow channels that are critical for GPU-intensive tasks. 3D printing breaks these chains. Using digital blueprints, we create geometries not possible with traditional technology—microlattices for heat dissipation, snap-in connectors that eliminate the need for assembly screws, or cavities that shield PCIe expansion.
Case Spotlight: Anatomy of Compact Metal Protective Covers
This custom case borrows the PCB specifications of the Raspberry Pi 5 and uses clever engineering:
- Dual chamber cooling: Separate compartments use integrated aluminum heatsinks that rise vertically through perforated sections to isolate SoC hot-spot exposure.
- Port accuracy: Laser-measured cutouts align perfectly with USB 3.0, Gigabit Ethernet ports—no need to plug into an Ethernet jack to remove dirt!
- Minimalist footprint: Measuring only 85x56x25mm, minimizing desk space while accommodating the GPIO access hatch.
- Installation versatility: The bottom groove is modified with M2.5 brass thread insert for VESA mounting or DIN rail fixing.
Frontiers in Materials Science: Aluminum SLM Printing
where is this huge light Change reliability. Using Selective Laser Melting (SLM) printers, we fuse ultra-thin layers AlSi10Mg powder Made into dense aluminum alloy blocks, it can provide:
- Excellent heat transfer performance: The thermal conductivity is about 140 W/mK, 300% higher than the silicone shell.
- EMI/RFI shielding: Blocks signal interference better than plastic – critical for IoT sensors near transmitters.
- Strength to weight ratio: Passed ASTM F3205 test and can withstand 120G impact load, very suitable for drone avionics.
Post-processing options deepen functionality: CNC milling ensures port openings have zero draft angle resistance. huge light Providing biosafety sandblasting or Outstanding anodizing (Clear/Matte Black), provides IP54 protection against moisture intrusion.
AlSi10Mg Raspberry Pi case is anodized – with optional laser etched logo.
Test scenarios and performance improvements
The embedded developer documented the upgrade process:
- robotics: SLM housing withstood 200 hours in automotive QA vibration testing—the wireless module stayed cool despite the SIM7600 constantly polling.
- Kiosk/NVR: Sealed finish stops particle buildup on fanless Pi 5 CPU in dusty Cairo deployment.
- tinker boost: Over-voltage I/O pins will never burn out the board – and thanks to the grounded metal casing, there will be no ESD failures even when touching the GPIO header.
Field testing exposes key Thermal: Stress test on Pi 5 CPU core (DRAM tuning loaded CPU) in ambient air at 26°C with heatsink assist 14℃ Compared to plastic sleeves.
| Case material | Idle temperature (°C) | Peak stress load (°C) |
|---|---|---|
| Basic plastic | 42 | 78 |
| SLM aluminum | 37 | 64 |
Engineering beyond prototypes – the manufacturing advantage
Rapid prototyping is not just about speed, it’s about precise adaptation. glorious Workflows help engineers thrive:
- Virtual CFD testing optimizes pre-printed airflow paths.
- SLM printers are built using layer-by-layer 200W fiber laser Melting micron-sized alloy powder.
- hot isostatic pressing (fashionable) Stabilizes microstructure – eliminates pores.
- Multi-axis CNC machining or grinding tolerance <±0.05mm.
- Custom coating – hardcoat anodized/electropolished – eliminates corrosion.
For the Raspberry Pi case, iteration cycles jumped from 14 days to <72 hours - all passed glorious ISO 9001 certified piping with documented PPAP compliance.
SLM chamber completes aircraft-grade Raspberry Pi enclosure.
Case closed – conclusion
The Raspberry Pi 5 requires 21st century technology for protection. Compact metal 3D printed enclosures break barriers through the elasticity and thermal ingenuity of SLM fabrication, transforming hobby SBCs into industrial-grade workhorses. For developers struggling with DC powered environments or high EMI protocols, using qualified aluminum enclosures can significantly reduce points of failure.
Dive deeper into: huge light Utilize SLM/SLS/DMLS to deliver custom metal enclosure prototyping—from design poetry to FAA-approved post-processing. Whether it’s a tricked-out Pi device embedded in an edge PLC or a drone flight controller, temperatures are no longer tolerated – they are controlled.
FAQ
Q1: Will SLM aluminum interfere with Wi-Fi/BT signals?
Surprisingly minimal! AlSi alloy can partially attenuate 2.4GHz waves, but can still maintain an uninterrupted connection within 10 meters (+2dBm TX). Separately shield the external LoRa antenna.
Q2: Can I install a cooling fan inside?
Yes, our parametric models include a 25x25mm blower cutout that connects to a baffle mounted flange to minimize clutter. PWM controlled airflow works against the throttling threshold.
Q3: Durability compared to CNC machined housing?
Through HIP optimization, SLM provides excellent fatigue resistance and improves the tensile strength of CNC aluminum billet (UTS close to 500MPa). Service life typically exceeds 8 years according to MIL-STD-810H cycle testing.
Q4: How is the compatibility of Raspberry Pi 4?
Misaligned ports can prevent Pi5/Pi4 swapping. We do provide support for a modified version of the Raspberry Pi Model B revision – specified during STL upload.
Q5: Does GreatLight offer flame retardant polymers?
For low-cost prototyping/testing, UL94 V0 rated PEEK/PA12 nylon options are resistant to ignition toxins, completing avionics FR certification.
Pre-release helps designers around the world replace cooling towers – one Raspberry Pi at a time. Where leads are unstable, compact SLM housings are put on.
Note: Raspberry Pi is a trademark of Raspberry Pi Ltd. Greatlight Precision Manufacturing specializes in aerospace-grade additive manufacturing – please contact our Guangdong headquarters at sales@greatlight.com for a quote "Pi case ready" Discounted prototyping.
