BeamCase SW - SFF sandwich case in 18 different sizes (7.2-10.3l)

BeamCase is a system that allows you to create your own case with the combination of 3d prints and Makerbeam XL profiles (or similar 15x15 aluminum extrusions).
BeamCase Sandwich is a system to create your own sandwich style SFF case that is the optimal size for your components. With 24 available sizes you can choose the optimal one depending on the size of your GPU and CPU cooler. By combining 3d prints and Makerbeam XL profiles the case is extremely customizable and strong at the same time.

The files for sale here include all the brackets to complete a frame in 24 different variations, as well as different case panel versions, case feet and brackets. There are more brackets available on my profile for free.
 

Choosing your size:

BeamCase Sandwich comes in 24 different sizes ranging from 7.2l to 10.9l. The difference between these versions is primarily CPU and GPU clearance. You can choose between 50mm, 60mm, 70mm, 80mm, 90mm and 100mm CPU cooler clearance and between 2, 2.6, 3, and 3.5 and 4 slots for your GPU.
(there is the option to also add a radiator for water-cooling, there are brackets available separately for free)

The default profile length is 300mm which enables the use of GPUs up to 305mm long (including the RTX 5090 FE). If you want to use longer GPUs you can buy longer Makerbeam XL profiles as this is the only thing defining the length of the case. (You can find longer versions of the case panels in a separate Printables post for free)

The limiting factor for GPUs is the height/width. The case has clearance for 137mm tall GPUs, 143mm for the 2.5 , 3.5 and 4 slot versions (+15mm for cable management), so the RTX 5090 FE will fit with 9mm to spare (+15mm for the cable). But GPU manufacturers are very inconsistent with that measurement, so this does not guarantee fitment. 

In terms of PSU the case is designed for an SFX and SFX-L PSUs, but SFX-L can conflict with the handle using 300mm long aluminum profiles (at longer lengths both can fit). 
This case theoretically fit Flex-ATX as well and some version even ATX PSUs, but I have not made any mounts for those configuration as they are very specific.

This is an intro intro and in depth assembly tutorial of BeamCase Sandwich.

This video explains the updates with version 2.3 (and shows the assembly of the largest version)

A V3.0 update video will follow soon. 

Updates:

V3.0 Update:

• New round case style with soft corners and large split lines showing the frame. 
• More sizes, 8 additional sizes for 24 in total. 
• New maximum width of IFW 150 and additional 4slot (82mm) GPU clearance. 
• Additional versions of the frame that support the use of heat inserts. (frame versions for heat inserts can be found in a ZIP file in the “Other Files”) 
• New 5090/5080 FE specific frame versions. 
• New one-piece case panels for large printers. 
• Additional case panel lengths for aluminum profiles up to 360mm long (separate Printables post)
• Additional one-sided PSU bracket, that only attaches to the aluminum profile on one side. 
• Slightly modified riser bracket to support specific PIE 4.0 and 5.0 double reverse riser. (new specific riser selected for PCIE 5.0 support) 
• Additional brackets for Linkup V3 double reverse riser (20cm) 
• The mainboard tray hole next to the PSU extension aligns with c14 screw in extensions for GPU clearance versions above 2-slots (42mm)

V2.6 Update:

• Added 1mm extra clearance between mainboard and mainboard tray, to minimize fitment issues. (to achieve this everything has been shifted which means there is no cross version compatibility)
• Overall improved frame structure which is even stronger than before.  (everything has been optimized a little bit)
• 2.5 and 3.5 slot versions have improved GPU height clearance at 143mm (6mm more then 2 or 3 slot versions)
• fixed position of the 4090/80 FE support, the GPU should clear the PSU bracket now.
• The top mainboard tray mounting bracket has been modified to give more clearance for the mainboard IO, but still connect to the extrusion on that side. 
• each complete frame file now includes the parts for a front with and without handle.
• added 5mm thicker PSU bracket for taller PSU extension plugs. 

V2.3 Update:

• added versions with higher CPU cooler clearance. There are now additional case versions with clearance for 80mm, 90mm and up to 100mm CPU coolers.
• added an additional position for a rear mounted power button (for options with CPU clearance of 60mm and above)
• added front brackets with integrated support for RTX 4090/80 founder edition
• added alternative mainboard trays with more clearance.
• added Pcie cover plates without the hole for a 16mm power button (they are in the frame files)
• more clearance at the PSU bracket (some Phanteks sfx PSUs collided with the bracket)
• added 3d printed replacements for 300mm Makerbeam XL profiles. These are a last option if profiles are not available. I do NOT recommend using them and do not guarantee fitment. 
• added STEP files of all the case panel versions. 

Required Hardware

Screws and nuts: 

• M3x8mm countersunk screws (I suggest at least 50 for a build)
• M3x16mm countersunk screws (I suggest at least 50 for a build)
• M3x20mm countersunk screws (optional but can be beneficial for front case panels)
• 6-32 unc screws around 16mm long for the internal sfx power supply (4pcs) 
• standard M3 nuts (and optionally thin M3 square nuts according to DIN 562 together with these nut-positioners)
• for the heat insert version m3 5.7x4.6mm inserts are needed (not needed when using pressed in nuts)
  
  I am located in Germany and buy my screws here.
   

Makerbeam XLprofiles (or similar 15x15mm extrusions suing m3 screws and nuts):
4x Makerbeam Xl profiles 300mm long (or longer depending on your desires size)

 

Power cable and button:

• The case has a spot for a 16mm generic power button at the back and the front, but other options are possible, with additional brackets. 
• For the internal SFX (or SFX-L) psu you will need a psu extension, ideally 30cm long and angled downwards (see video for details). I am located in Germany and bought this one, but similar ones can be found on Aliexpress.
   

PCIE riser:

• The case requires a double reverse riser 19-20cm long. 
• For a PCIE 4.0 riser I bought this one from Amazon which has been very reliable and you can find it in many different stores under different brand names. (reference pictures are included in the files)
• For PCIE 5.0 riser I bought this one of Aliexpress (19cm), which fits in the same mount (v3.0). It is very compact and slim, and 19cm is just about long enough. 
• I have also made brackets for the Linkup ver.3 double reverse riser, it has to be the ver.3 riser, the ver.2 Linkup reverse riser will not fit. (the Linkup riser is not compatible with the 5090FE frame)

Components structure and naming:

All the components for a frame version are in a single STL file, which has the CPU and GPU clearance in the file naming, as well as an IFW number. IFW stands for Inner Frame Width and describes the distance between the Makerbeam XL profiles at the top, front and bottom. The IFW number is an indicator of the width of the case and is important when selecting accessories and case panels. 
Each frame file also comes with an slim top mainboard tray bracket, this only needs to be used, if the full width one collides with a large mainboard IO cover. 
 

 Print Instructions frame:

All the 3d printed parts for a basic frame are in a single STL for each version. Before you print it you will have to separate them into individual objects in your slicer (use the function “split to objects” for that). Then you can use “auto orient” and arrange to  place them optimally.  
These parts should be printed in somewhat heat resistant materials, PETG or better ABS. All parts are designed to be printed without supports, but a skirt is advised with the larger pieces.
The frame parts should be printed with at least 4 walls and 35% infill in order to be strong enough.
You should consider shrinkage of the material as the parts have to be precise in order to fit properly. (I used Sunlu ABS and adjusted for shrinkage by scaling everything to 100.5% but some people were able to print it in PETg without any scale adjustments.)

Print instructions outer panels:

Like the frame parts all panels for a size come in a single STL file and must be separated using the function split to objects. 
To get the mesh you have to reduce the top and bottom layers to zero. This exposes the Infill which acts as the mesh. The case in the images shown uses honeycomb Infill with a density of 18%, but you can play around with different patterns and density, just keep airflow in mind. Additionally, I use 6 walls for the case panels to add strength around the edge. (disable “one wall on top layer” to consistently have 6 walls)

With V3.0 of BeamCase sandwich there is now the option for one piece case panels that do not have the split along the length, but these do require a print bed of at least 318mm in length.

The case panels are primarily aesthetic so they can be printed in any material you like (in some rare cases PLA panels can deform with high exhaust air temperatures). For the panels to fit perfectly they have to be printed accurately, so ideally consider shrinkage. 
Usually, these panels shrink less than the frame parts as they are printed very open. (for ABS I set scaling to 100.35% for the case panels)

Printer Requirements:

You will need a print bed at least 195mm long and between 125mm and 175mm wide depending on the selected size. 
If you want tp print the case panels in one piece you will need a print bed at least 318mm long. (the split panels have the same print requirements as the frame)