PiBoy DMG Custom Rear Case With Ventilation

thingiverse

Custom rear case for PiBoy DMG with significant additional ventilation to stock case. Especially useful if you are using a Raspberry Pi 4. There are 2 versions of the case provided: i) With Pi supports. This is exactly the same as the stock case but with significantly more ventilation and has the same 4 x internal pillars used to clamp the Raspberry Pi onto the mounting points. ii) Without Pi supports & with heatsink cutaways. This version is best used with my custom Pi Supprt brackets (thingiverse item https://www.thingiverse.com/thing:4940588) in conjunction with a suitable heatsink. I use the 2mm copper heatsink which is available from many places including Ali Express. This version of the case provides room to properly secure the heatsink to the holes nearest the battery case, as well as removing the Pi support poles as these are not required. To get best printing results with a single extruder printer, you are best orienting the case with the external side facing down, and supports are required. I have tried various slicer settings and the best I came with up was 0.4 nozzleusing Prusa Slica supports - as these came off the easiest and left fewer marks to clean up afterwards. The attached photo shows what I achieved with ABS straight off the printer after removing supports, and before any post processing. I also attach some Pi benchmarks, which were acquired using StressBerry over 30 minutes running a number of different case configurations. These are not real world tests, but give a comparison across the different setups. In summary, a 2mm copper heatsink, with a 8gb Pi4 overclocked to CPU2147 and GPU750 barely gets to 50 degrees C in real world use - even on heavy duty emulation such as Dreamcast. The 2mm copper heatsink I use is here: https://www.aliexpress.com/item/1005001691525070.html This heatsink requires the edge nearest the battery tray to be trimmed - the best option is saw through the centre point of the rear mount holes straight across, so that half the mounting hole remains. This give you enough copper to properly screw it down, and provides enough clearance from the battery tray. I recommend you print this with ABS if possible, as I'm not sure whether PLA will withstand continued exposure to the internal temperatures that these get up to. But I guess you can always print another case if it does warp!