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-   -   WIP Project HELIOS - Invocation Begins 10.01.10 (http://www.hardwarecanucks.com/forum/case-mods-worklog-gallery/36337-project-helios-invocation-begins-10-01-10-a.html)

Langer September 17, 2010 06:54 PM

Project HELIOS - Invocation Begins 10.01.10
 
HELIOS, the Titan god of the sun. Tireless is he who is like the deathless gods.
As he rides his chariot, he shines upon men, and piercingly he gazes with his eyes from his golden helmet.
Bright rays beam dazzlingly from him, and his bright locks streaming from the temples of his head gracefully enclose his far-seen face.
A rich, fine-spun garment glows upon his body and flutters in the wind: and stallions carry him.
Then, when he has stayed his golden-yoked chariot and horses, he rests there upon the highest point of heaven, until he marvellously drives them down again through heaven down to the lasting earth.

http://www.jesselang.ca/helios/log/H...teaser-001.jpg

Design Features:
- Crafted from the worlds highest grades of composite materials and carbon fiber.
- Showcasing some of the finest watercooling components and computer hardware.
- Designed to hide every fastener, nut and bolt.
- A lack of case windows leave the motherboard bare and exposed.
- High-tech and specially engineered ceramic foam filters and stainless steel mesh keep out dust.
- Made from virtually indestructible panels over 8MM thick.
- Taking advantage of air pressure zones to keep hardware dust-free.
- Fully removable motherboard tray without disconnect or power-down.
- Highly modular design makes part-swapping as simple as possible.
- Sleek minimalist design is a call back to swiss modernism and bauhaus principals.
- Design and fabrication methods tailored to an extreme rapid fabrication cycle.
- HELIOS is to be a scratch build mod, truly, like no other.

Hardware List:
Computing:

Processor - 1x unknown
Graphics - 3x nVidia GeForce GTX 480
Motherboard - 1x unknown
Memory - 12GB unknown
Power - Corsair AX1200
Storage - 8x 120GB SSD
Display - 3x Asus VW266H 25.5"

Cooling:
Processor - 1x AquaComputer Cuplex Kryos XT
Graphics - 3x unknown
Motherboard - 1x unknown
Radiators - 2x HW Labs GTX480 (3x140mm)
Tubing - 20' Tygon AS600038
Fans - 13x NB-BlackSilentPro PK-3
Pumps - 4x Laing DDC-1plus
Pump Tops - EK-DDC Dual Top V2
Memory - Mips RAM Kόhler6
Fittings 1 - 10x 3/8" Straight Rotary Fitting
Fittings 2 - 20x 3/8" 45 Degree Rotary Fitting
Fittings 3 - 20x 3/8" Angle Rotary Fitting
Fittings 4 - 10x Low-Profile Stop Fitting
Fittings 5 - 16x Fitting Spacer
Fittings 6 - 16x Mini Fitting Spacer
Fittings 7 - 8x No-Spill Quick Disconnect Female
Fittings 8 - 8x No-Spill Quick Disconnect Male
Fittings 9 - 4x 2-Slot Crystal Sli-Link Tube
Fittings 10 - 3x Mini Sli-Adapter

Fasteners and Hardware:
Polyethylene Spacer - 40x 3/16”OD x .115”ID x 3/8” (McMaster - 92825A009)
SS Dowel Pin - 50x 3mm x 6mm (McMaster - 91585A051)
SS Press-Fit Threaded Insert - 5x 1/4-20 x 1/2” (McMaster - 92394A116)
SS Press-Fit Bushing - 4x .257”ID x 1/2”OD x 1/4” (McMaster - 8492A155)
SS Knurled Thumb Screw - 4x 1/4-20 x 3/4” x 1” (McMaster - 91830A577)
Wool/Rayon Adhesive Back Felt - 1x 24” x 32” x 3/64” (McMaster - 8770K3)
SS Low Head Socket Cap Screw - 75x M4 x 30mm (McMaster - 92855A425)
SS Knurled Thumb Screw - 24x 6-32 x 1/2” x 1/4” (McMaster - 91746A536)
SS Low Head Socket Cap Screw - 25x 6-32 x 3/4” (McMaster - 93615A210)
SS Self-Lock Flat Head Cap Screw 25x 10-32 x 1” (McMaster - 92805A268)
SS Male-Female Standoff - 18x 6-32 x 3/16”OD x 3/16” (McMaster - 91075A461)
Hinge / Lid Support - 2x 1.744” x 5.313” (McMaster - 14785A51)

Materials:
- 8MM thick CNC cut carbon composite panels crafted to the strictest military specifications
- 2MM thick thermoset carbon composite panels made for aerospace applications
- Stainless Steel hardware throughout
- Stainless Steel micro-weave mesh
- Felt dampening
- Polyethylene to reduce friction in modular areas.
- Custom engineered ceramic foam air filters

Specifications:
Size - 206mm Wide - 610mm Tall - 610mm Deep
Weight - unknown
Performance Statistics - unknown


Design, Prototypes, Mockups and Fabrication log to follow.

Langer September 17, 2010 06:54 PM

Concept, Design and Planning
First Stage 3D Mockups

Langer September 17, 2010 06:54 PM

*reserved for final/current image*

Langer September 17, 2010 06:54 PM

INITIAL CONCEPT ILLUSTRATION:
Using Adobe's Illustrator I created a couple rough perspective drawings, so that I could get a better idea of the concept in my head:
-At this point the plan was to construct the case in Aluminum.
http://www.jesselang.ca/helios/log/Helios-iso-01.png


REVISION 1.0:
http://www.jesselang.ca/helios/log/Helios-r1-01.png


REVISION 2.0:
After talking with the community and doing some more planning myself, I made some changes to the plan.
-Altered some of the chassis dimensions.
-Trashed the idea of stacked radiators.
-Relocated the pumps and reservoirs.
-Added a downward facing PSU fan, which would later be scrapped.
-Finalized the tubing layouts.
-Changed from 360MM radiators to 420mm
-Changed the fabrication material to Grade 38 Titanium
http://www.jesselang.ca/helios/log/Helios-r2-01.png


REVISION 3.0:
I again posted my designs for the community to critique and made some very minor alterations yet again.
http://www.jesselang.ca/helios/log/Helios-r3-01.png
http://www.jesselang.ca/helios/log/Helios-r3-02.png


REVISION 4.0:
At this point I was getting some really good feedback online and started putting it into practice.
-I redrew the entire design with new dimensions.
-Plotted the wiring paths.
-Refined the tubing layouts.
-Finalized the pump and reservoir positions
http://www.jesselang.ca/helios/log/Helios-r4-01.png
http://www.jesselang.ca/helios/log/Helios-r4-02.png


PAPER PROTOTYPE:
It was now that I decided to take my design and bring it into the physical plane. The medium I decided upon was cardboard and tape - the board I used is the same stuff one would use to matte pictures when framing.
http://www.jesselang.ca/helios/log/H...ototype-01.jpg
http://www.jesselang.ca/helios/log/H...ototype-02.jpg
http://www.jesselang.ca/helios/log/H...ototype-03.jpg
http://www.jesselang.ca/helios/log/H...ototype-04.jpg
http://www.jesselang.ca/helios/log/H...ototype-05.jpg
http://www.jesselang.ca/helios/log/H...ototype-06.jpg
http://www.jesselang.ca/helios/log/H...ototype-07.jpg


REVISION 5.0, current and FINAL revision:
Happy with the prototype and the general concept, I decided it was time to finalize the plan and fix the little issues. This revision I've kept to myself until this now. I've made many very small changes to the plan.
-I again completely redrew the design, this time with 8MM thick paneling.
-I added small routered grooves where the panels fit together to better hide the seams.
-Altered the relationships of components and their positions.
-Finalized the design for the PSU cavity.
-Beveled all the edges of the cuts - to compensate for the diameter of the 1/8" cutting tool on the CNC router.
-I also swapped out the Titanium for a Carbon Fiber construction instead (I'm going to save the Titanium I acquired for another project down the road).
http://www.jesselang.ca/helios/log/Helios-r5-01.png
http://www.jesselang.ca/helios/log/Helios-r5-02.png
http://www.jesselang.ca/helios/log/Helios-r5-03.png
http://www.jesselang.ca/helios/log/Helios-r5-04S.png

Langer September 17, 2010 06:55 PM

I've been working with an engineer, and friend of mine named John Dalton, who has graciously offered up some time to throw together a 3D mock-up.

He sent me off the first revision of his model today.

There are couple of minor errors, due to my vague explanations:
-In this model the motherboard backplate is flipped 180deg
-The SSD mounts are affixed to the side panels instead of the rads
-the motherboard tray is just floating in space.

They are such minor issues that I have no problem at all sharing some previews with you.
And John already agreed to rectify the issues for me on Monday.

Here's an ISO view with perspective.
http://www.jesselang.ca/helios/log/Helios-model1-01.jpg

Side view with perspective:
http://www.jesselang.ca/helios/log/Helios-model1-04.jpg

View of the back and side of the chassis.
http://www.jesselang.ca/helios/log/Helios-model1-05.jpg

A couple of detail shots of the bottom.
http://www.jesselang.ca/helios/log/Helios-model1-03.jpg

Note here how I managed to save some space by routering out some spots in the chassis and side-panel. These will allow for a couple extra millimeters for the pumps and PSU fan.
http://www.jesselang.ca/helios/log/Helios-model1-02.jpg

You can CLICK HERE for a live model preview which you can rotate around and navigate in 3D space.
Unfortunately this HTML export from SolidWorks is only supported by IE, and on PC.

mattlef September 17, 2010 07:36 PM

I'm a huge fan of your work. Really looking forward to see what you have planned.

LaughingCrow September 17, 2010 07:37 PM

Presumably, the machining and working with graphite composites (highly conductive) will be kept separate from electronic gear? Clean room assembly?

(Used to work at an aerospace firm that manufactured aircraft parts, satellite parts from graphite, Kevlar, etc., vacuum bonding, water-jet cutting, etc.)

Langer September 17, 2010 10:27 PM

@mattlef - Thank you very much mate.
@LaughingCrow - Negative on the clean-room. But the manufacturing and assembly will be happening at different sites. Thank you for commenting.

That's all I have to share for today.
I'll have the revised model as well as some renderings to show you all next week.
As well, next week, I'll share some pictures of the manufacturing process behind the composite panels. Perhaps even some shots of them being CNC cut to spec.

*j

martin_metal_88 September 18, 2010 08:23 AM

Ho god Langer, this is very sexy and awesome! Can't wait to see it runnong and to dream if only I could make one :( Carry one my friend!

Toyoracer September 18, 2010 08:35 AM

Langer, looking at your drawings. Your second revision of airflow has it exhausting back on your GPU's and very close as well. Have you considered having rads sideways or same intake but exhaust backside.


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