Custom 3D Printed Case for HP MicroServer N40L

This is a custom-designed 3D printable enclosure made specifically for the HP MicroServer N40L.
The case is designed from scratch to properly fit the original hardware layout while offering improved airflow, modular construction, and easy access for maintenance and upgrades.

Key Features

• Designed specifically for HP MicroServer N40L
• Multi-part construction for easier printing and assembly
• Front-mounted 80 mm fan for improved airflow and cooling
• Integrated ventilation grills for passive airflow
• Internal mounting rails for drives and internal hardware
• Removable top/lid panel, secured with screws
• Cutouts for rear I/O, power connector, network port, and expansion slots
• Robust construction for long-term durability

Panel Thickness

• All panels are designed for 3 mm thickness
• Do not scale the model, as this will affect fitment and alignment

Assembly Instructions

• Side panels and bottom panel must be glued together
• Recommended adhesives:
  • Cyanoacrylate (CA / super glue)
  • Epoxy (for maximum strength)
• The top/lid panel remains removable and is secured using screws
• Test-fit all parts before gluing
• Allow glued joints to fully cure before installing hardware

Printing Recommendations

• Recommended infill: 50%
• This infill percentage is required for structural strength
• Suggested slicer settings:
  • Layer height: 0.2 mm
  • Walls / perimeters: 4–5
  • Top / bottom layers: 6+
• Recommended material:
  • PETG (preferred)
  • PLA is usable but not recommended for warm environments

Cooling

• Front fan mount supports a standard 80 mm fan
• Fan screws mount directly into the printed part
• Ensure correct airflow direction during installation

Screws and Heat-Set Inserts

• Heat-set inserts are required for all screw connections
• This allows:
  • Strong and durable threads
  • Repeated opening and closing without damage
• Install inserts using a temperature-controlled soldering iron
• Do not force inserts into cold plastic

Notes

• Verify all cable clearances before final assembly
• Check airflow path before running the system
• This case is designed for experienced makers and modders

Disclaimer

This is a community-made, non-official design and is not affiliated with HP.
Use at your own risk. Always test cooling and component fitment before running production hardware.