Custom Aluminum Hardcase/Briefcase..

I'm in the midst of building one right now for my beloved Envy 14. I would like to see if there is any interest in some hardshell cases. I'm not exactly what to call it at this point. It is going to be a hybrid..half briefcase half rugged sleeve.

As a bonus when the laptop is removed the case will function as a souped up heatsink/laptop cooling pad. It will allow heat to quickly dissipate and either keep the laptop or your legs cool while using it on your lap.

This case will be designed to be used with a neoprene sleeve or other similar sleeve. It will provide protection of the edges as well as direct hits on the lid or bottom of the laptop case. In a future rendition perhaps it can be fitted to work well without aid of a sleeve. This case will provide the ultimate protection to the corners of your laptop as this is where it will be strongest.

Materials wise the two sides of this case will be made from 6061-t6 aluminum. As to the thickness my prototype will be made from 1/8th thick. ( Far to heavy to be practical, but it was easy to source) I've had these cut by a CNC waterjet for accurate clean lines/holes. I'm going to be testing different materials to edge it, if I find that is even necessary, I'm unsure of how smooth the edges will be after epoxy coat has been applied.

In a future rendition I would limit the material to 14 Guage ~1/16 thick which would bring the total weight in at ~ 3.5 or so lbs. or less while retaining unbelievable strength.

For the standoff bolts surrounding the case I will be using Stainless bolts and aluminum spacers. It gives it a nice clean look without adding unnecessary weight.

I will be finishing with a clean brushed look and a clear epoxy hard coat intended for aluminum wheels.

For the handle, so it is comfortable to hold I will be neatly wrapping with black paracord. It should add comfort and durability.

As for how the laptop stays in when shifted, the two slots near the top of the case will be sliding posts with small aluminum/plastic knobs that will be able to lock it in place. Teflon washers will allow it to move smoothly without scratching the aluminum finish. ( This is admittedly difficult to describe, photos coming later this week)

I'm basing my design off of this Iphone 4 case

I'm going to be putting it all together this weekend so photos will come.

High density EVA foam can line the inside walls just as it does in that Iphone Case.
In my prototype model I'm not including it as the BUILT neoprene sleeve I've got should provide more than enough protection.

I know this is short on detail and specifics so do bear with. I will be posting further information this week as I finish it off.

This is a photo of the cut profile for the aluminum. It is simple but I feel that it is quite functional and comfortable to hold ( cardboard mockup).



I would love any suggestions/comments/helpful tips! Please!!! This is my first case endeavor and I would love your feedback.

If I get a lot of feedback and my prototype turns out as well as hoped I would love to sell a few of these! Let me know if your interested at all. The more interest I get the more likely I will be able to do it for a reasonable cost.

I can also modify the design to suit any model/make as long as I have the dimensions.

 

This is a quick mock up I just put together...the design is terribly difficult to visualize without a side view.

 

I'ts a nice idea. One word of warning - the design won't deal well with drop impacts if you design it around the 'posts' idea, even sleeved. Given the forces involved concentrated around the area of each standoff 'post' and the amount of padding on a typical sleeve, you're almost guaranteed some denting on the notebook. You'll need to spread out the effective load over a wider area.

 

very nice idea. but 2 suspended plates will be pretty prone to crushes and flex with the post layout. I would look into a way to run a lip into the bottom and side, edges at minimum to make it a bit more rigid.

ideally some sort of support structure to lessen the flex and stop the posts from digging in when dropped as vogel said. a drop onto small surface areas = trouble

 

I wasn't talking about the plates really - once you make them thick enough / establish the profile to hold the structure, what you're referring to won't be such an issue - especially as the notebook will be inside, and let's face it - this is a fairly cosmetic exercise. We're not talking Otterboxes.

I'm simply talking about the impact of the notebook against the posts. I quite like the idea as it stands, but as I said you'll need to increase the contact area of each support and the notebook.

 

Sorry, I re-read and editited my post as you were posting and corrected that oversight. forgive me as eyes and brain is buggy from replacing LCD panels in some MBP's

 

Thanks for the input! I see where you both are going. I'm going to have it fully assembled this weekend and I'll try to work out the kinks. It is possible that I will be able to bend in the free edges of the aluminum on the bottom and the side to add some more stability and protection.

Another suggestion was to semi-suspend the entire laptop in paracord..I'm going to see if I can work with that, at least at first because it will be reversible.

 

or cut an aluminum U to go around the inside of the standoffs it will brace and give the surface area to stop point cracks and dents

 

That would be a very quick and easy solution! I have access to a full metal shop so I should be able to put that together. On the inside of the U I could line with thin layer of EVA foam for shock protection.

 

sounds like a plan coming together to me.

 

That would be a quick fix as long as the sheet gauge is thick enough to prevent deforming with the same issue.

I do like the idea of 'open sides' better though from a looks perspective (although you could drill the U for a semi-open look, even if you had foam behind it). Try the U first, but I'd also suggest keeping the original idea but with much more flattened-out/wider standoffs.

 

agreed or drill a few hundred holes in the metal U and make it look like an industrial grate or vent. ( got a CnC drill, router or end mill there OP )

 

Love the semi open idea!! I can get it CNC cut... I'm pushing for EVA foam on the inside of the U..

 

I'm already working on a slimmed down version... Using a soft plastic handle with tough nylon straps and a heavy duty Velcro clasp that will solidly hold the laptop comfortably.

I would use the hollowed out inner U with the same size standoffs and 1/4" Eva foam on all 4 sides so it. Can be used without a sleeve and would weigh in at sub 3 lbs... Post more later!! Keep up the great ideas

 

Gave one outward facing side a brushed finish for photos.

As suggested the handles are too far apart. I've decided that a future revision will include a soft thermo-formed handle with high grade nylon strapping.

I will be including a EVA foam padded aluminum inner U with some grill like design for aesthetics.

I'm unsure of the clasping mechanism at this point. ( I could use suggestions here)

I also will be cutting weight by using 1/16 thick aluminum rather than the current 1/8.

Weight per side is ~ 2.4 lbs right now. Will be about 1.1 lbs after revision.

I will eliminate the current 'breifcase' style and opt for a cleaner rectangle with no protrusions. This should add strength and stability while limiting the weight.

Still looking for any tips or tricks you have! Please!! I've been inspired and plan to continue this.

I'll try and finish off more of the current design just to see how it pieces together, but it will not be a logical solution as it currently weighs in at about 5.5 lbs.

 

Buy a Rimowa case?

-> Easier....

Also, you'll want a well designed handle - a good case can be killed by a bad handle, especially if you don't add a shoulder strap.
I'd also suggest a structure from the side - also to hide the contents, if you are worried about air flow, then try a wire mesh, but technically something thin could hit the laptop between the metal sheets.

 

Nice going.

Clasp-wise, I think you could pivot a formed alloy sheet-strip (in the same manner as the drilled U) around one of the top standoffs and have the strip run across the top, with either a mechanical or magnetic engagement against the opposite top standoff.

I've always found Rimowas fugly in the extreme - always gravitated to Halliburtons instead. Of course, these days we use Hardiggs / Pelicans.

 

-> Do looks really matter if it's practical and it looks practical? On that note...

I wonder if I can consider getting one this summer... or should I stick to my messenger bag....

 

WELL...after a long hiatus I've completed a revised edition of this case! Fully functional and very slick looking, I hope you will agree.

Some snaps are below.











The case faces are brushed 1/16th 6061 Aluminum with a clear epoxy overcoat for protection. The inner "U" is formed from 6061 brushed aluminum as well with an inner layer of EVA foam and a layer of UHMW tape to decrease friction.

The top is a sandwich of a layer of brushed aluminum on the bottom and top with a laser cut piece of 3/8" black acrylic in between for additional strength.

Some finish work still needs to be done on the top layer, but I don't have the time to complete that right now, so it will have to wait.

The webbing is all high grade polyester and extremely smooth to the touch.

The inside of the case is 1/4" Black EVA foam with a layer of UHMW Teflon tape to lower friction. The case is perfectly sized for the envy 14 to sit on top when not in use.



The clasp is a small powder coated steel hook connected to the lid by strong 1" wide webbing and elastic.

This will likely be my final revision but I would love to hear comments and thoughts about it. ( Perhaps I'll implement some more changes.) Questions are always welcome! And even offers to buy it ! ( I spent a small fortune getting it all made, but I don't believe I will end up using it myself but I would like it to get some use.) PM me or post if you are curious...

In closing I want to say that I know it isn't perfect, but for something done in my spare time, it turned out quite well. While it my not suit the needs of everyone it would definitely work for some.

 

I must say I love it Lazbee, fantastic job on the revision.

 

Excellent job! I love it, makes me think if you could design one that would act as a ergonomic laptop cooler w/ fans maybe. Once again very nice job, I'd like to see a video of it and it's features, reading and photos aren't enough xD

 

Thanks for the support! -- As to a video I'm flat out of time these days, but I'll try and put something together.

 

With a few small tweaks and some very thin fans I could make it work without huge modifications.


Oh on another note...With a small modification to the clasp and lid it would be nearly waterproof, at least highly resistant. Enough to be safe out in the rain for some time.

 

Very nice! Quite impressive, definitely a DIY masterpiece. I agree though on making it waterproof, that would complete the "bulletproof" look.

I'm not sure how fans would work though, and I think it works fine for what you set out to build. If you wanted fans, you could do a DIY cooler

 

Just a suggestion
Since you have access to all materials and tools, why not make something like this?
Laptop opens as you open the case and start working on it right away.
Bottom part of the laptop can be fixed (clamped) to the base aluminium as well as the screen
can be clamped to the top cover.
Once you are finished close it and it is a bullet proof case.
Just a suggestion don't get me wrong.

btw it is a quick sketch, has to be worked on it especially on the hinge part so
laptop can be opened as you open the case.
It is not hard though

 

I had considered something like the clamshell you describe originally, however I had to abandon that design because of a few major issues....and personal preference..


I believe it could work...however if you were to use the laptop, and this clamshell case were to provide protection, the vents would have to be left clear and holes would need to exist through the case for cooling. If you had any foam lining the inside my guess is this would be quite dangerous for the laptop as it might seal up any air intake...

I'm not sure if those issues would come up in the design you propose, but let me know!

 

I like that quite a bit! But try getting that through airport security, lol.

 

It's just a gigantic piece of metal, nothing to worry about

I'm pretty sure the Aluminum top itself would work decently enough for cooling, just raise the back of the laptop and done

 

I suppose it should work as a good enough heat-sink. As for airport security, it wouldn't be an issue. A pass through x-ray and it would be very obvious nothing dangerous was inside. It is essentially just two pieces of aluminum sheeting, not dense enough to block anything inside. No worse than a briefcase.

 

It is really cool though. It's something I could see people using out in the field. Have you considered selling these for a living?
I think it's a great design.

 

I have considered selling them, but I've run into the issue that each laptop is different in size and they would have to be custom made, thus greatly increasing the price of each case. Maybe there is a market out there, but I'm a novice when it comes to starting a business.

So I can push forward to develop some more, I would like to sell this prototype. Its not a perfect specimen but damn well functional.