Orange Pi Zero 2 casse with expansion board & heatsink

thingiverse

Summary ==================== Orange Pi Zero 2 with expansion board and aluminum heatsink & aluminum base plate as could be bought from [AliExpress - DIYZone Store - Bundle 8](https://www.aliexpress.com/item/1005004072696767.html). I deliberately didn't punch a hole for the 3.5mm jack, since I read this was not connected with the Pi Zero 2. Also depending on the materials you print this, the IR sensor wouldn't be of any use. Microphone the same. I created cutouts to allow airflow in and out over the heatsink. Plan is to place it in the airflow of the exhaust ventilator of my power supply. But from what I've seen so far, the OctoPi doesn't get warm and one might as well leave the fan out of the game and attach it vertically, allowing warm air to exit the case at the top. I use this to control my printer using OctoPi (and klipper in the future I hope). The additional USB ports of the expansion board are great to drive a webcam. Additional Materials ==================== * 2x M3 inserts * 2x M3x8 screws * 4x M2 inserts * 4x M2x30 screws (unfortunately I didn't have them, so went with M2x20s but can't reach the lid, is I'll have to glue in the lid :( ) What to improve? ==================== Top / Main Case --------------------- It is really fiddly to screw the extension board in and plug the Pi in afterwards. Maybe a little more air gap around the pi would help. Be careful when placing the inserts! Not much wiggle-room in the design. Lid / Lower Case ------------------- The antenna could be held by some ribs on the lid. But this could make it even more of a hassle to assemble this. When using long M2 screws and connecting upper case, OctoPi and lower case together, you'll need some washers as spacers. Otherwise the OctoPi wouldn't be held in place. Maybe re-design the lower case to hold it in place. The hoist points on the lid are a little flimsy. I would suggest to make the lid a little thicker. But then we may need even longer vertical M2 (or M2.5) screws...