Custom Hard Case for Envy 14 And more

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.

 

I don't get how this design works. My brain is probably just off. I'm confused about the holes and their purpose. Maybe some more designs will help clear it up.

 

Don't fret! Not just you that doesn't understand...I seem to have made a VERY confusing post I'll try to clear it up with some photos in a few minutes.

 

This is a side view of a really quick mockup I just put together..I hope this helps a bit more...one more photo coming along..

 

This is one of the 10 bolts and spacers that will be surrounding the laptop, keeping it safe and in place. Stainless screws/bolts and aluminum spacers.



I hope that begins to explain the design. Thanks for taking a look! I really need to feedback. I'll incorporate it into a future version for sure!

 

I think I get what you're doing. You just want two metal surfaces attached with those metal posts. So it's acting like a cradle. Since you're going to use paracord for the handle I think it would look nice if you wrapped paracord all along the open part where the laptop touches the posts to spread out some of the pressure points and make the case look like 1 piece. Maybe consider putting hinges on the handle parts so they wont be so spaced part when you hold it.

 

As for the handle, I agree it would be great to be able to hinge that. I had thought of it but disregarded because I felt a cleaner look would be perferred..I'm going to have the finished piece in hand friday..I'll see how it handles then.

Paracord all around might be a great idea...it would give a bit of cushining and 'suspend' the laptop..I have many things to experiment with

 

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.

 

Wow this is really cool!

Where does one get that aluminum from anyway? (I'm not gonna be making one, but I'm just really curious) heheh.

Keep up the good work!

 

It looks very attractive but kind of bulky. I can't see myself carrying that around.

Great work though.

 

Yes, it is bulky! This is built from 1/8th thick aluminum!

I will be slimming it down to half the thickness and eliminating the handle so in essence the case will be a hard shelled laptop sleeve.


THIS one weighs over 6 LBS

The next version will weigh well under 3, perhaps ever 2 LBS.
Don't be entirely dissuaded by the bulkiness of this one

I have a feeling you will be quite attracted to the slimmed down revision.


As to how these were cut...They were designed in a CAD program and cut by a cnc Waterjet. The edges are very nicely sanded and the brushed finishing is done by hand after cutting.

 

Ok the problem I see with a metal sleeve is that its kind of pointless. I mean if you're going with a sleeve you're going to either hold it in your hand or put it in a bag. Since I personally see holding a sleeved laptop pointless you're gonna want to put it in a bag. I don't know how a metal sleeve will fit in another bag. You need something that fits like a glove and is soft to be a sleeve. I don't see how you're going to take the laptop out of a metal sleeve assuming you made it small enough to not be so bulky. It would have to be slid out and in and with a foam interior that makes it tough.

If you want to make it a thin metal container then just make it like a briefcase and have 1 lid be a flap on a hinge and have a small clasp that locks it in place. Make it out of anodized aluminum and foam line the inside. You can even have a simple detachable handle to make it briefcase like.

 

In response to how I will get the laptop out... The most logical solution that I can think of would be think, PTFE 'teflon' sheets on top of the foam. It would be a sandwich of aluminum-eva foam-teflon strips.

This combination would both make a very stable construct and and easily accessible pocket.

I can understand the hesitation about what this really is, is a sleeve or is a briefcase, or something else? ( At this point I'm trying for a combination of the above)

I'm still going to have a handle attached, though instead of aluminum I would be using strong nylon webbing so as to give it both strength and the ability to remain lightweight.

This is still a work in progress, so don't expect a flawless product right away. It is coming together nicely so far, and the second iteration should answer some, if not all, of your concerns.

 

If this is something that you want or need, then go for it, it looks pretty cool, and the sense of achievement from creating something like that yourself is huge. However, it doesn't really fill a need for most consumers, so don't expect to find too many people buying them - a single-function case of that size would have a hard time competing with softer sleeves that are smaller and lighter and can be put into backpacks and messenger bags, or multi-purpose laptop bags that can carry other stuff as well.

The biggest flaw in the comparison with that iPhone case (which is a bit bulky looking but cool as well) is that the iPhone case is designed to allow the iPhone to work unhindered inside the case, but that doesn't translate for a laptop computer with the hinged lid (not that you would want a laptop running inside a case lined with high-density foam for very long at a time).

Anyway, a summation: this is a very cool project that you're working on, and the finished case is sure to draw a lot of admiration as something you made with your own ingenuity and work. If your primary goal in designing this is to sell these cases, however, I suspect that overall interest would be minimal, since it's made to do one job excessively well, when there are cheaper, more convenient, multi-functional alternatives for that same job. I'll put it this way: if you were to carry this into a room full of a thousand Envy 14 owner/enthusiasts, you would be the talk of the party. If, however, you brought in a hundred of them and tried to sell them at a reasonable price, you'd probably find it to be a losing proposition. A handful, a couple dozen, possibly, as long as an exclusivity factor was maintained, but it's very much a niche product.

 

If everyone listened to every critic nothin g would ever get made. I say great idea. This is just the start of something that could end up completely different over time. Go with it. Worst that could happen is you're back to where you started. If selling them is even the point of this.

 

I appreciate your encouragement! I'm not really sure where this will end, in profit or in disgrace. Either way I'm enjoying the process, and if there is a market for it I'll sell a few.

 

I'll restate that I think this is a very cool project and you deserve major props for going for it. It looks like you've got a good attitude toward it as well - if it flops, it flops, and if it takes off, great. Any updates on your progress in the past few days, or are you waiting for parts?

 

I've worked out a cleaner design and sent it off to be cut from some more realistic material, 1/16 thick aluminum. This version will include a sturdy shoulder strap and soft thermo-form handle.

As for the current design I've brushed all the sides and have just received the epoxy clear-coat that I'm going to use. I need to wait for a warmer day, but hopefully I'll have a clear answer as to if it will work soon. I'll try to post some more photos tomorrow.

 

great work...But its seems that you made too much specific..means for a particular one..

south-pak.com

 

Please translate

 

You mean to say something about how it will only work for the specific laptop it was designed to? At this point it is only for the envy, but I hope to adapt it to others. Second version has parts arriving right now..hopefully by weeks end I'll have some more photos of the updated version.

Note that this new one has a great shoulder strap and better locking mechanism.
I'll keep you all updated ASAP. Sorry for not adding more sooner, but as I'm waiting on specialty parts it takes a while for them to come in.

 

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'm sure someone will mention this...but space for accessories would be needed. I've designed either a pouch for the large flat side or thin side to hold the power adapter and a few small items. They would be detachable neoprene, but I just didn't have the time to devote to getting them sewed and finalized.

 

wow awesome case

 

Thanks!


Also, if anyone is curious -- I haven't done any testing as to its durability so far...and I don't really intend on it, but it should take a beating before anything happens to the laptop. (or so I hope.)

 

Nice job! I think it's awesome you did all that yourself! You could even get creative and engrave things into the case, like initials or your favorite sports team logo or something.

You know what else would be interesting? A small hole on the side near the power adapter input so you could charge it while it's in the case. That could be useful if you ever had it charging in your car or if you just wanted to charge it without pulling it out of the case.

 

I hadn't thought of that before...I wonder though..wouldn't the laptop get too hot while charging in an enclosed space? ( It would be a very easy change if it was safe)

 

Got dang! It's good to hear from you again

That's a darn nice case you got there. Can you share some additional photos of the top/closure, and what it looks like when you open it to gain access to the lappy? I hope I phrased that adequately.

 

I'll get a few more up tomorrow..maybe have time to shoot a video.

I will be the first to admit it does look somewhat odd when open, but how often will it be left open anyhow? Also my sewing skills leave something to be desired. I can redo the clasp very easily with a proper sewing job, so it is not a permanent error.

 

OoHHOOHHOOOOOOooooo I see now, it's a hook thingy (aka clasp?) that wraps around the rod. Neato. But isn't that kinda risky if you're moving around? Maybe it can wiggle off and kablam! The lid comes off and byebye E14??

Also, whered you buy the strap materials and handle?

 

Not sure...does it even get hot when it charges? I mean...it shouldn't since the only thing that should really be getting any juice is the battery. The drives and processors should remain powered down, so really it shouldn't get too hot I would think.

 

?? Wrong thread?

 

The clasp is held fast by a strong elastic band on the underside of the strong 1" poly webbing. It keeps the tension so the clasp cannot release unless you want it to. Also, when you apply upward pressure (eg. the handle) you are switching the load from the elastic to the strong webbing, so it takes the brunt of the load and keeps the lid on.

Strap materials and handle were sourced from Strapworks.com and a few local shops.

 

Nope, we were discussing the ability to charge the laptop while it was in the case. I had suggested a hole in the bottom of the case to feed the power cord through but we don't know how hot the computer would get while charging in the case.

 

Woops my bad. It seems that a hole in the side of the case would be better, so that you don't smash the cord.

 

No worries. I say "bottom" of the case out of habit because my Acer has the input for the power cord on the back. With the HP ones being on the side, a hole could be placed on the side, near the bottom of the bag. Might be more applicable for someone who has more than one power cord though.

 

It's not hard to find a spare. Or, he can sacrifice his OEM one, and buy a universal Kensington one for the future.