I designed this enclosure for my Home Assistant instance. 

It runs on a Raspberry Pi 4, with a nvme USB adaptor and a Raspberry Pi PoE+ Hat. Because the room the instance is installed in can be a bit warm, I included a A6x15 PWN Noctua Fan.

The enclosure is 150mm wide, 240mm deep and 88mm high (2U in a rack).

To connect the RJ45 cable, I use an adaptor to mount it on the face of the enclosure. I also used USB adaptors for the Zigbee dongle. I plan to have another one for Thread / Matter when neccessary, that's why I designed the back piece to host 2 adaptors.

Every piece are connected using Ruthex threaded insert:

• 4 x M2.5 to connect the Raspberry Pi to the Connector
• 4 x M4 to connect the Connector to the bottom plate
• 24 x M3 to connect all the piece

I used countersunk head screws ; 12mm long for all the M3 and 8mm long for the M4. I also used countersunk screws for the fan, with square nuts to hold it. The Raspberry Pi nvme board is fixed to the connector using standoff.

The fan is connected to the Raspberry Pi on port 4-6-8 for +5V-GND-PWM. On HA, I'm using https://github.com/RedMeKool/HA-Raspberry-pi-GPIO-PWM to be able to control the fan speed with an automation based of the CPU temperature.

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I printed the elements in PLA Silver Gray. At .2 layer height, with 3 perimeters. I encourage to use the 3MF file at least to get the bottom piece, as there are modifier to have more perimeters for the M4 threaded inserts, which requires thicker walls. Others, as printed sideway, don't have any problem.

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Changelog:

  * 2025-01-11: I moved all ports on the same facade. Fan is now pulling air out. I reduced the depth of the box (240mm to 220mm), width and height are the same.