Anker PowerExpand Elite 13 in 1 Dock Holder

Anker PowerExpand Elite 13-in-1 dock with 120mm Fan

Design Goal

This is an updated version of my WD-15 USB-C dock (https://www.thingiverse.com/thing:4335172) and subsequent WD19TB dock (https://www.thingiverse.com/thing:4633066). I picked up a Framework (https://frame.work/) laptop, and the WD19TB doesn't play nice with it, so I went hunting for a new dock. What I landed on required a new holder for the dock. A lot of the below is copy/pasted from the WD19TB dock thingiverse page. The specific dock is available here: https://www.amazon.com/gp/product/B087219P5J/

The design goal was fairly simple: Minimize the foot print of the dock and laptop while still providing cooling to the laptop's bottom. I usually leave my laptop closed while docked so, if I stand everything up it should be fairly easy to keep the foot print down significantly.

It's designed to fit a XPS 13 9370 and Latitude 7390, but also fits my new XPS 15 9500 without any real issue. I did confirm the Framework fits as well. Most thin and light style laptops should work just fine. I did end up moving around some of the cabling again to account for differences in the docks.

By standing the dock up as intended, with the cable running thru the hole in the center pillar, I can put the laptop with it's back facing the other direction, feed the USB-C cable thru the front, and have a fan blowing against the bottom of the laptop. The far left side features a diamond shaped lattice to hopefully allow some airflow to the dock to help keep it from over heating.

Design wise it's really quite simple. The "left" slot is for the dock, there's a slot on the middle separator to feed the USB-C cable thru, and the laptop rests on the right. The cutout for the fan is for a standard 120mm computer fan (I have a few laying around). It includes cutouts for nut on the "inside," but using more traditional case fan self-tapping screws should work. Even standard M4 screws are held in place without nuts somewhat securely (depending on your printer's tolerances that may or may not be true for you). There's a little cubby under the fan with a cutout to route the fan's cable.

Bill of Materials

Required:

3D printer and filament (inb4 someone points it out in the comments)
120mm 3 or 4 pin fan
3/4pin fan to USB (for providing power)
4 screws M4/case fan tap screws for mounting fan

Optional:

120mm case fan dust filter
4 screws for mounting dust filter (if using above)
4 to 8 M4 nuts (4 if using M4 screws to mount fan, 8 if using M4 screws to mount fan and filter)

Note on the 3/4pin fan to USB power adapter:
I had purchased mine from Fry's well before they closed permanently. There are a lot of case fan to USB powered adapters available on Amazon but nothing quite like what I have.

How to use it

The STL is already oriented for printing. In case your slicer imports it wrong, the "back" side should be on the print bed. This will mean the dock side with the grating is on the left, the fan cut out on the right. Obviously, rotate how you will and the left/right won't be accurate anymore, but live your life. If your printer has solid cooling you can print without supports. I used PrusaSlicer support enforcers to get a cleaner top of the fan hole cutout, but otherwise nothing.

Mount the fan as you wish. I used M4 16mm screws and M4 nuts because I have bunch laying around. I also mounted a case fan filter to the fan itself with more of the same screws and nuts.

Put the dock on the left, standing up so the the side opposite the USB-C cable is facing the bottom. Feed the USB-C cable thru the back side of the cable route so it comes out the front of the printed part.

You're basically done. Drop your laptop on the right with the underside of the laptop facing the fan, back (where the hinge is) facing the bottom of the part, and plug your USB-C cable in.

Optional, but I used some Command Strips to mount the dock in place on my desk. Some rubber feet or something would probably help, too. I suggest the command strips or similar products to "fasten" the dock in place so the weight of the cables that plug into the dock don't tilt it around too much.

Print Settings

Printer Brand:

Prusa

Printer:

I3 MK3S

Rafts:

No

Supports:

Yes

Resolution:

.2

Infill:

15

Filament: Prusament PLA Galaxy Black
Notes:

Since you'll be holding something of not insignificant weight in it, and screwing stuff into it, I suggest 3 perimeters and ~10-15% infill. Material choice likely doesn't matter, if your laptop, and ultra book sized one none-the-less, is getting hot enough to damage PLA even with a fan blowing on it, you have bigger problems.