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 18 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 18 different variations, as well as different case panel versions, case feet and brackets. There are more brackets available on my profile for free, but some are only compatible with the larger BeamCase SFF. 
 

Choosing your size:

BeamCase Sandwich comes in 18 different sizes ranging from 7.2l to 10.3l. 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 slots for your GPU.
(there is now the option to also add a radiator for water-cooling, the 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 4090 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. 

The limiting factor for GPUs is the height/width. The case has clearance for 137mm tall GPUs (+15mm for cable management), so the RTX 4090 FE will fit with 10mm to spare (+15mm for the cable). But GPU manufacturers are very inconsistent with that measurements, so I will release a 3d printable template soon, that you can use to test the fitment of your GPU. 

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)

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 beneficial for 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)
  
  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)

 

Powerbutton:
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. 
 

Cable:

• PCIE riser, the case requires a 180 degree 20cm long riser. I bought this one from Amazon, but the same one can be found in many different store. (reference pictures are included in the files)
• Internal PSU extension, 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.
   

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:

The panels have two parts in each STL, to print the fan grill/mesh pattern reduce the top and bottom layers of the inner part to zero, this way only the infill will be printed and act as a mesh. You can choose an Infill pattern you prefer, but for good airflow I would choose an infill percentage between 12-18%. (the case in the images uses grid infill as a mesh pattern and infill percentages between 12-16%)
These parts are primarily aesthetic so the can be printed in any material you like (in some rare cases PLA panels can deform with high exhaust air temperatures). In order for the panels to fit perfectly they have to be printed accurately, so ideally consider shrinkage. 

Printer Requirements:

You will need a print bed at least 195mm long and between 125mm and 175mm wide depending on the selected size.