MDF CNC'd 21L PC Case

Overview

Role - Mechanical Designer | Product Designer | CNC Fabricator

Tools - AutoCAD, Fusion 360, FDM 3D printing, 3-axis CNC Router

Skills - CAD Design, Rapid prototyping, Mechanical design, Manufacturing, Hardware integration, Testing & validation, Toolpath creation, Assembly systems, Product Development

Design Process

The objective of this project was to design and manufacture a compact PC case system that combined a functional test bench architecture with an enclosed aesthetic shell, while being fully manufacturable using a 3-axis CNC router, a 3D print, and standard off-the-shelf hardware.

The design was developed using a hybrid manufacturing approach, combining CNC-machined MDF components, a single CNC-machined acrylic top panel, and 3D-printed structural elements integrated with standard hardware. The system was designed to balance manufacturability, rigidity, and visual presentation while maintaining compatibility with commonly available PC components.

MDF was selected as the primary structural material due to its low cost and ease of machining on a 3-axis CNC router, enabling rapid fabrication and iterative development without requiring specialized tooling.

A key feature of the design is an internal structural frame system that functions as a fully open test bench. This inner frame supports both ATX and Micro-ATX motherboards, allowing the system to operate as a flexible hardware development and benchmarking platform independent of the outer enclosure.

The outer shell uses friction-fit joinery, eliminating the need for adhesives while maintaining rigidity through tight tolerances and mechanical interlocking features. All external visual components are held together through compression and fit-based assembly rather than permanent bonding.

The outer shell is designed as a sliding enclosure that integrates around the internal test bench structure. This separation allows the system to function both as an open-access test bench and a clean enclosed desktop PC case.

CNC toolpaths were generated in Fusion 360, with all MDF and acrylic components designed specifically around 3-axis machining constraints. The acrylic top panel provides direct visibility into the system, and an integrated LED strip was added to highlight internal components and improve visual presentation.

Results

The completed system resulted in a ~21L PC enclosure that successfully combines a rigid internal test bench structure with a modular external shell.

The internal frame provides a stable and reusable platform for hardware testing, supporting both ATX and Micro-ATX systems while maintaining strong airflow due to its open architecture. Under sustained loads, system thermals were maintained below 65°C, attributed to unobstructed airflow paths and minimal internal restriction.

The hybrid manufacturing approach successfully integrated CNC-machined MDF, a single acrylic top panel, 3D-printed components, and standard hardware into a unified system that does not rely on adhesives or permanent bonding methods.

The friction-fit structural system proved effective in maintaining rigidity while simplifying assembly and enabling repeatable manufacturing using a 3-axis CNC workflow.

Overall, the design achieves a balance between functional test bench performance and enclosed case aesthetics, reducing desktop footprint while maintaining accessibility, airflow, and visual clarity of internal components.