Overview#
Designed and manufactured a custom 3D-printed rack mount for a Mac Mini, iterating through 16 prototypes in just 3 days to achieve optimal fit and functionality.
The Challenge#
Create a rack-mountable enclosure that:
- Securely holds a Mac Mini in a standard networking rack
- Includes integrated ethernet keystone jack
- Minimizes vertical space usage
- Can be printed on a consumer FDM printer
My Approach#
Rapid Iteration Strategy#
With only 2 prints possible per day on my printer, I developed a workflow where CAD changes outpaced physical prototyping. Many designs became obsolete before they could be printed, driving efficient decision-making.
Early Prototypes#
Initial design had issues:
- Unoptimized geometry for print bed orientation
- Mounting holes in poor orientation for clean printing
- Loose and weak ethernet keystone mounting
Final Design#
Key improvements in the final version:
- Moved Mac supports from underneath to sides, reducing vertical space
- Optimized print orientation for clean hole printing
- Tight, secure fit for keystone ethernet jack
Installation#
Final placement in the networking rack, alongside another simpler rack mount of my design.
Results#
- 16 prototypes in 3 days
- Significant reduction in rack space usage
- Clean, professional appearance
- Secure mounting for both Mac Mini and ethernet keystone
Key Skills#
- CAD: Rapid Design Iteration
- Manufacturing: FDM 3D Printing, Design for Additive Manufacturing
- Engineering: Space Optimization, Tolerance Design
- Process: Parallel Development (CAD ahead of prototyping)