Project: Helios | concept and design

[Langer]

Hello everyone, Langer here.
I'm close to wrapping up my last mod - some of you may know about it, PrometheusCU.

Being that I'm all excited about modding again I spend yesterday planning out my next build; Helios.

Some of the more unique design considerations:
- Helios will be made entirely from plated 6mm thick aluminum
- The entire chassis construction will use no screws/nuts/bots/glue/fasteners/etc
- 90degree motherboard mounting format
- The motherboard will be exposed as the entire chassis is 'doughnut' shaped
- 2-watercooling loops with 4 radiators
- Extreme minimalist design will hide ALL non-essentials


I'll leave the rest to more-or-less speak for itself:

ISO View:
http://www.jesselang.ca/helios/images/helios-concept-1-iso-view-01.jpg

Exploded View:
http://www.jesselang.ca/helios/images/helios-concept-1-iso-view-02.jpg

Open side view with cooling loops and airflow:
http://www.jesselang.ca/helios/images/helios-concept-1-left-view-01.jpg

Open side view with cooling loops:
http://www.jesselang.ca/helios/images/helios-concept-1-left-view-02.jpg

Open side view:
http://www.jesselang.ca/helios/images/helios-concept-1-left-view-03.jpg

Open top view:
http://www.jesselang.ca/helios/images/helios-concept-1-top-view-01.jpg

Bottom view:
http://www.jesselang.ca/helios/images/helios-concept-1-bottom-view-01.jpg

Parts schematic PDF:
http://www.jesselang.ca/helios/images/helios-concept-1-parts-01.jpg (http://www.jesselang.ca/helios/documents/helios-concept-1-parts-01.pdf)


One thing that I learned this past year, and a major focus in my life at the moment, is project management. What that means is that unlike PrometheusCU this project will be planned to the T before commencement, and it will have an incredibly rapid timeline... I'll also be building 3 of them.


All the drawings were done in illustrator.
The isometric view and the exploded view were created using a projection technique as old as time itself used in perspective drawing.
http://www.jesselang.ca/helios/images/helios-concept-1-perspective-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-1-perspective-L.jpg)

Please leave your comments, suggestions and considerations.

I'm still trying to decide what exotic material to plate this beast with - if anyone has any suggestions let me know.

There's a small chance that I may bite the bullet and build it out of pure Titanium. I've been speaking around, and would be able to aquire the necessary Titanium plates for only ~10% of retail.... unfortunately that's still about $2800 in raw metal costs alone.

Speak your minds, let me know what you think.

*j

[diluzio91]

mmm... you know what looks sexy? tungsten carbide... Some of the most beautiful metal i have ever seen... no idea about price though...

http://www.halesowen.net/images/tungsten-carbide-rods.jpg

[Ilden]

Like I said elsewhere, honeycomb Kevlar. ;)

I actually looked into tungsten, but ruled that out as a suggestion when I saw the weight. A case made from tungsten would weigh like 300 pounds.

[Langer]

But it may be possible to plate a lighter metal in tungsten carbide... ATM, I'm leaning between an 8mm thick composite panel used to armour plate nuclear submarines, plated aluminum, or titanium.

Here's a preview of how it will be assembled.

Some parts fit together like a puzzle, while others will be fit together with steel dowel pins, press-fit and stealthed:
http://www.jesselang.ca/helios/images/helios-concept-1-fasteners-01.jpg

And here are the dimensions:
http://www.jesselang.ca/helios/images/helios-concept-1-measurements-01.jpg

[Kayin]

What about some of that nickel-CF composite you have lying about? Good damn that stuff's awesome.

Trying to beat my record of most expensive material for a case?

[raistnox]

if your going for most expensive why not go for solid gold or platinum lol im kidding looks like a cool design though

[Luthien]

Fitted together like a puzzle or using steel dowels to put it all together...Interesting way to connect pieces...Cool

As for metal, perhaps you could use one metal for the main color and plate small accents with another material. I like the combination of silver (main part) and rose gold (accents).

[knowledgegranted]

Your going to want to cool the CPU first, from experience, cooling the chipsets first makes the CPU cry and unhappy.

[SXRguyinMA]

doesnt it not matter once the fluid reaches its equilibrium temp?

[Langer]

I'd like to invite everyone who is interested to follow me on my Facebook page.

Of course I will still be updating on the forums, and on my website, however the JLI Facebook page will be the best source for up-to the minute updates on my projects (new and old), exclusive info, and prize details.

JLI Facebook Page (http://www.facebook.com/pages/jli/113753835322772)

*j

[Langer]

Greetings one and all!

I present, for your viewing pleasure, revision 2.0 of project Helios

As per the suggestions of the community, this revision, although almost identical to the original is actually a complete redraw taking into account many oversights in the first design.

This revision see's the following changes:
- new, smaller, custom reservoirs made from 0.25" acrylic
- revised construction material from 6mm aluminum to 0.25" titanium
- altered dimensions to accommodate 420mm radiators
- completed the PSU installation and wiring configuration (not shown below)
- adjusted loop orientation for cleanliness
- altered air-flow direction
- augmented fastener design (not sown below)
- new space for SSDs, eight in total
- the motherboard try no-longer 'slots' into the bottom as it did in the first revision, instead it there is a space accentuating how it hangs from the top
- more are was taken into removing the motherboard tray, it will now easily slide out the top
- whereas before only the left side panel was removable, now they will both be totally removable (in seconds without any fasteners or latches)

*click for huge*
http://www.jesselang.ca/helios/images/helios-concept-2-loop-01-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-2-loop-01.jpg)
Here you can note the new size to allow for the 2x 420mm Rads (Hardware Labs GTX420)
The fans will be Noiseblocker PK3's (7 of them)
The new reservoirs will need to be custom made, I'm leaning towards having them mill from solid acrylic
I've also added 4x SSD racks, to-be mounted directly to the radiators, this will allow for a total of 8xSSDs to be installed.
There is exactly enough room in the bottom section to mount a stripped down and modified Corsair HX1000


*click for huge*
http://www.jesselang.ca/helios/images/helios-concept-2-parts-01-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-2-parts-01.jpg)
Apart from the rads, and the reservoirs the design is pretty much the same as it was.
All the dimensions are completely different however


*click for huge*
http://www.jesselang.ca/helios/images/helios-concept-2-airflow-01-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-2-airflow-01.jpg)
The airflow is now pulled from both the front ad the back.
Since there is no side window, and the components are totally exposed the air will simply vent out the bottom and the sides.

*click for PDF download*
http://www.jesselang.ca/helios/images/helios-concept-2-parts-02.jpg (http://www.jesselang.ca/helios/documents/helios-concept-2-parts-01.pdf)
Take a closer look, download the PDF and give the parts a once, over.

I'm really looking for constructive feed-back.
Please leave your comments or suggestions, help me improve this design and consider the unconsidered.

Don't forget to become a participating fan of JLI on Facebook for all kinds of insider information, prize opportunities, and special treats. JLI Facebook Page (http://www.facebook.com/pages/jli/113753835322772)

*j

Thanks again, and tune in soon.

[Langer]

Please take note - THERE ARE NO WINDOWS.... THE CASE HAS A 13" SQUARE PUNCHED RIGHT THOUGH THE MIDDLE; A GIANT OPEN HOLE WITH A MOBO FLOATING IN THE MIDDLE.


The airflow is now pulled from both the front ad the back.
Since there is no side window, and the components are totally exposed the air will simply vent out the bottom and the sides.

There is a actually a box with a PSU inside above the bottom fan, it receives it's air from the front and back and pushes it out the bottom; however the vast majority of the air gets pushed out the sides over the motherboard and into the ethos of our atmosphere.

[Langer]

A couple of really quick mock-ups to make some of the details and the airflow more apparent.

http://www.jesselang.ca/helios/images/helios-concept-2-airflow-02-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-2-airflow-02.jpg)

http://www.jesselang.ca/helios/images/helios-concept-2-airflow-03-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-2-airflow-03.jpg)

[x88x]

Intriguing...very interesting design, and I love the full-titanium construction. :twisted: I'll definitely be keeping my eye on this.

OOC, why 3? Are you selling two off or what?

Also, should that be 13 fans (not 7)?

[Langer]

Thanks for pointing out the fan miscount man.
As for my reasons... all will be revealed in time

======
Hello all once again - and hopefully this will be the last of these planning installments.

I'd like to share with you the third and final (for now) revision before this plan hits 3D mock-ups.

A quick overview of the features and design details presented thus far:
- Room enough for and easy access to 2x420mm Radiators
- Integrated reservoirs and 4xPumps
- Constructed from 0.25" Grade 38 Titanium plate
- Motherboard can be removed without disconnect from tubing or wire harness
- All wires are run out the top and back of the chassis, which also creates a storage cavity
- Absolutely no visible fasteners on the chassis
- The case will be held together without the use of screws, fasteners, bolts, or adhesives
- Will features 2 independent cooling loops
- Blacked-out and filtered air intakes in the chassis
- Side panels will be removable in seconds without any latch, fastener, or tool
- All bolts, fittings, and hardware will made from be stainless steel
- All bushed and nickel plated cooling gear
- All tubes and wires will be sleeved in milspec quality nylon multifilament sleeving
- There will be no side windows, instead the components will be exposed to the elements
- The entire chassis will feature some type of exotic coating, such as a rubberizing perhaps

======
Here's change-log for revision3.0:
1) Pumps have been flipped and are now side mounted - pumping upwards
2) Custom reservoirs replaced with EK (possible IandH) options mounted directly to pump-top
3) Tubing layout redesigned to consider a more efficient routing
4) Much more finite consideration of power and data wire routing
5) Altered position and orientation of modified PSU, fan now blows up and wires run out the front/back of the PSU
6) Moved location of chassis USB ports and power switch to the motherboard tray backplane

======
Revision 3.0 Side and Top views with cooling loops:
http://www.jesselang.ca/helios/images/helios-concept-3-loops-01-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-3-loops-01-L.jpg)

Side and Top views with parts only:
http://www.jesselang.ca/helios/images/helios-concept-3-parts-01-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-3-parts-01-L.jpg)

Side and Top views of empty chassis:
http://www.jesselang.ca/helios/images/helios-concept-3-chassis-01-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-3-chassis-01-L.jpg)

Side view detailing roughly how the wires will be routed, note how the wires are fed out both the front and back of the PSU:
http://www.jesselang.ca/helios/images/helios-concept-3-wires-01-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-3-wires-01-L.jpg)

Here's a very rough perspective view of the bottom most cavity, showing how the pumps, PSU, and reservoirs are oriented:
http://www.jesselang.ca/helios/images/helios-concept-3-iso-view-02-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-3-iso-view-02-L.jpg)

Here's a perspective side view to add a bit of depth, this just details some of the design features:
http://www.jesselang.ca/helios/images/helios-concept-3-iso-view-01-S.jpg (http://www.jesselang.ca/helios/images/helios-concept-3-iso-view-01-L.jpg)

Taking into the account the vast array of suggestions on the latching/fastener method I made a revision. This particular design was suggested by Oldnewby - thanks mate:
http://www.jesselang.ca/helios/images/helios-concept-3-fasteners-01.jpg

======
Don't forget to follow me over on Facebook:
Tune in on the JLI Facebook page for exclusive info, and prize opportunities.
BECOME A FAN OF JLI (http://www.facebook.com/home.php?#!/pages/jli/113753835322772)

======
Thanks for the suggestions and help everyone - watch this space in the coming weeks as this design unfolds to become a reality.



*j

[Langer]

A user by the name of NFC over on the XS forums presented a very interesting point to me this afternoon. I think it would be a good opportunity to share the concern, and express my beliefs and intentions.

======
NFC put this concern before me:

It's beautiful. I'm also concerned that case manufacturers might try to glean potential IP from it.

Like, I would hope you would want to share the ideas with the community for their own personal projects, but you give an awful amount of insight to people who could lock others out from doing it.

======
Here's my response:
You present an interesting point, however the mass publication of this project across about 35forums, the 6000+ image views per day, and the collaboration with sponsors (coming soon) is a pretty big deterrent. It would be very easy to defend this in an IP battle, considering that there is clear evidence that I published it first technically I'd have rights.

Regardless of all that, absolute worst case scenario (pun intended): I have dozens of other designs floating around up in the old noggin, I'll just move onto a new one. I plan on releasing my own line of cases in the coming future - this project is merely a bloated prequel.

I do this because I absolutely love doing it. Moreover I love to share, get feedback and work collaboratively with the community - if I get shafted by some manufacturer of cases then sobeit. In the long-run it would better benefit everyone if the idea was ripped off - it's about time we saw someone rethinking this sh*t on mass scale (key word being think... there's alot of useless plastic bullsh*t cases out there that put 0 thought into enthusiast usage)

Truth be told - I conceived the entire concept in an afternoon, with the exception of maintaining the threads that go along with it I have only about 30 or so hours invested so-far.



The following is quoted from my website's about-me page (http://www.jesselang.ca/about-me/):

Question: Why do you share your UX resources so openly? (this mantra applies to all my design, not just UX)

Too long has the high-tech industry been protecting it’s interests through, what I have titled, the acquire and archive model. Which entails buying out conflicting ideas, or merging with competitors in the interest of shelving perfectly viable and beneficial technologies. I believee in the spirit of open co-opatition, abelieff which stresses the idea of sharing knowledge with everyone -especiallyy competitors. Because it’s only when we embrace new-age movements like open-source development, and the digitization of the worlds libraries that we will really be able to take the next step.

If I were to fully consider the issue you have presented I would be breaking my core principal.
If I stop sharing, then I stop getting critical feedback, and I don't get to potentially inspire others (a deep honor in my opinion)
If I patent the design I become the very evil I try to contradict.




On an up-note: I'll continue to share me ideas on a finite level - with the intention to have the community guide my decisions.
There will be mock-ups and 3D visualizations to come soon.

I love little mental paradoxes, and I tend to over think things. As I sit here contemplating this situation I keep thinking about the barber paradox:

Suppose there is a town with just one male barber; and that every man in the town keeps himself clean-shaven: some by shaving themselves, some by attending the barber. It seems reasonable to imagine that the barber obeys the following rule: He shaves all and only those men in town who do not shave themselves.
Under this scenario, we can ask the following question: Does the barber shave himself?
Asking this, however, we discover that the situation presented is in fact impossible:
If the barber does not shave himself, he must abide by the rule and shave himself.
If he does shave himself, according to the rule he will not shave himself.

[Langer]

I've scratched my head at this dilemma all day now... and here's what I've done for the modder's everywhere:

http://www.jesselang.ca/helios/88x31.png (http://creativecommons.org/licenses/by-nc-sa/3.0/us/) <--click for details

I've put a creative commons licence on the design

You are free:
to Share — to copy, distribute and transmit the work
to Remix — to adapt the work

Under the following conditions:
Attribution — You must attribute the work in the manner specified by the author or licensor (but not in any way that suggests that they endorse you or your use of the work).
Noncommercial — You may not use this work for commercial purposes.
Share Alike — If you alter, transform, or build upon this work, you may distribute the resulting work only under the same or similar license to this one.

With the understanding that:
Waiver — Any of the above conditions can be waived if you get permission from the copyright holder.
Other Rights — In no way are any of the following rights affected by the license:

Your fair dealing or fair use rights;
Apart from the remix rights granted under this license, the author's moral rights;
Rights other persons may have either in the work itself or in how the work is used, such as publicity or privacy rights.

[Langer]

Greetings, ;)

There's been a small change of plans... I'm having some custom super high-tech 0.25"thick carbon fiber panels made for this project, as opposed to the titanium as planned. I may still make one from Ti because the idea excites me, but the short term will not see that happening.

When the carbon arrives in a couple weeks, I'll begin cutting.
For fun today I decided to throw together a prototype... at least that was the plans before it took me near 6hrs to make.
It ended up taking a long time because the art framing board was really REALLY tricky to cut with a little type-A x-acto. this unfortunately also affected the bud quality as well... but im still fairly pleased.

I'll let the pics do the rest. I present the latest iteration made from Art Framing Board and Silicone Tape. ;)
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-01.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-02.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-03.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-04.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-05.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-06.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-07.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-08.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-09.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-10.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-11.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-12.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-13.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-14.jpg
http://www.jesselang.ca/helios/images/helios-concept-r3-prototype-1-15.jpg

What do you think? Leave a comment, let me know while there's still time to change plans before I begin cutting.

*j

[diluzio91]

this makes much more sense than the drawings did to me. Cool design!

[Langer]

Thank you very much.

------
The above wasn't my first attempt at fabricating this design in this method.

First I made a smaller iteration - 30%, whereas the above prototype is 40% scale - however lack of experience in working with the Framing board and attempts to glue the thing together lead to a failure.

As you'll see in the images below, at first I tried to make it in a printer friendly card-stock... but it was too flimsy and I didn't feel like laminating several sheets together. This would prove to me a mistake later on, lol.

I glued the cardtock pieces that I had printed and cut earlier to a sheet of Framing board. My intention was to use the printed pieces as guides, without realizing just how hard it is to cut Framing board... let along Framing board with an extra layer of cardstock and some hardened white-glue.

I'll share with you my first attempt nonetheless, it will still give some insight into my method and tools. ;)

Again, pictures talk:
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-01.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-02.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-03.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-04.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-05.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-06.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-07.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-08.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-09.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-10.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-11.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-12.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-13.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-14.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-15.jpg
http://www.jesselang.ca/helios/images/helios-r3-prototype-fail-16.jpg

Take care, ;)

*j

[billygoat333]

holy hell this mod is shaping up to be awesome! not sure exactly how I missed this. good work and keep it up!

[Langer]

Thanks a lot man - it'll be much more fun when it starts for real.

[Kayin]

Excellent work-but what happened to the Istanbul project? I know you're not dropping Becktons in here...

[Langer]

I have some beastly machines at my access now, I have no immediate demand for the 16core monster... but I still very much want to build it (AMD has 12core chips now... so I'd be more interested in a 48core rig).

Moving into a loft space in Sept with a shop in the basement... it will grant me my long awaited freedom to build as I could when I was back in Ontario.

[Luthien]

12? 16? 48?
Man, that's a lot of cores....Cool

[Langer]

http://www.jesselang.ca/helios/images/good-news.png

The high-grade composite panels required for construction of this project are being manufactured this week!

The panels in question are 16mm thick and composed of an astonishing 52layers. (The details of manufacturing will be released with the update... there's some CRAZY science and pressure involved to achieve the desired effect).

The panels are being made from an incredibly high grade of carbon usually reserved for military aerospace applications. In addition there are some other composite materials intermixed in the lay-up which will add some unique properties - but I don't want to say more and ruin the surprise.

I will have the panels in my hand in 2-3weeks, then I'll be sending them out for cutting straight away!

I'm elated that this is coming together as planned. I hope you will all enjoy the show, and if that's not reason enough for you, I plan on accompanying the commencement of Helios with an update on my PrometheusCU (http://forums.bit-tech.net/showthread.php?t=154608) project as well.

Tune in soon for more...

[msmrx57]

Good news indeed. :up:

[diluzio91]

lol.. thanks... now every post i read is gonna sound like farnsworth... But lets make with the update already!

[Langer]

Haha, thanks gentlemen. All in good time, and not much longer now.

[Langer]

A 'small' order today from McMaster - the necessary stainless steel hardware, fasteners, and misc. bits needed to assemble this project:
http://img.photobucket.com/albums/v60/Langer/misc/helios-mcmaster.png
I can feel the enormity of the cost of this project already...
the parts to hold it together cost $1,180.03USD+tax and shipping.

The choice for stainless bumped up the cost considerably... but it's just too sexy to resist.

Now I'm just waiting on the composite panels that will compose the chassis to come in from California... I'm not even going to hint at how much the panels cost, and they need to be machined to spec still.

I still havent yet decided on the final hardware configuration, but I am sure it too will put a good dent in the old wallet.

*j

[x88x]

the parts to hold it together cost $1,180.03USD+tax and shipping

:eek: That's just absurd. ...*looks over at watercooling system* ...never mind, carry one... :whistler:

[SXRguyinMA]

lol