ITX Case for PfSense / OPNsense Firewall / Router REMIX

thingiverse

I scoured the internet for an ITX case for a pfsense build I wanted to do. I didn't want something as large as some of the ITX cases on here that support full length GPUs. I also wanted the NIC above the board. Lastly, I wanted a standard internal power supply. After many minutes/hours searching, I found lowfat's case. It was almost exactly what I was after, but his design was purpose built for the hardware he had. Luckily, lowfat supplied the step file which I could import into Fusion360 and get to work. I present my take on the Mini-ITX pfsense router case. **THIS IS A WORK IN PROGRESS AND I HAVEN'T PRINTED IT YET!** **Requires 11x10 or larger print bed. If you lop off the PCIe mount tab, 11x9 would work.** **Changes made:** <ul> <li>Made the PCIe slot universal. This will fit a half-height PCIe card. The front tab is held in place by 1 or 2 3mm screws and nuts/washers. The bracket ear is held in place by a 4mm or 6-32 screw and nut. The card slides into the slot from the back. This was a design choice I had to make to make the mount universal while still making it easy to disconnect ethernet cables.</li> <li>Extended width and added mounting location for a TFX power supply. I don't know if the ones with a bumpout fan will fit. I allowed a 5mm gap in hopes that it will. I went with TFX because SFX didn't make as much sense. TFX are cheaper and fit the form better.</li> <li>Extended depth 1". I wanted to add fans to the front. There are now 2 80mm fan mounts.</li> <li>Moved power button to the front. It's a 12mm diameter just like lowfats.</li> <li>Obviously I had to extend the top. I removed the top mount fan and added slot mounts for a 40mm x 10mm fan. The slots allow you to move this into the best position to cool your add-in NIC. Print the top upside down as the fans are partially inset into the top.</li> <li>Added mounting holes for the 2.5" HDD/SSD.</li> <li>Added integrated motherboard standoffs. Standard 6-32 computer screws(psu/case screws) should thread in just fine.</li> </ul> **Hardware needed to assemble:** <ul> <li>PCIe bracket - (2) 3mm x 10mm screws and nuts. (1) 4mm x 10mm screw and nut.</li> <li>Motherboard - (4) 6-32 computer screws.</li> <li>Power Supply - (3) 6-32 x 3/8" screws.</li> <li>80mm fans - 4 4mm x 15mm screws and nuts. Or 4mm x 35mm. Maybe standard fan screws?</li> <li>40mm fan - Doesn't seem to be standardized. Ranges from 3mm to 4.3mm. The slots are 3.2mm for versatility. So (4) 3mm x 15-16mm plus nuts should work for both. Might need washers for fans with the larger hole size.</li> <li>2.5" HDD/SSD - 3mm x 5mm.</li> <li>Top - (8) 4mm x 10mm screws.</li> </ul>