Chassis Design
This page covers chassis design options — from 3D printed designs to a premium CNC-carved wood alternative with laptop hinges. Choose your approach based on available tools, materials, and aesthetic preference.
Design Approaches
Two primary construction methods, each with their own advantages:
🖨️ 3D Printed (PLA/PETG)
Quick iteration, low material cost, easy to modify. Adapt existing designs or create from scratch. Good for prototyping and functional builds.
→ Jump to 3D Printed Section
🪵 CNC Carved Wood
Premium aesthetic, superior durability, satisfying heft. Uses proper laptop hinges and magnetic closures. More tools required but results in a genuine piece of craftsmanship.
→ Jump to CNC Wood Section
Option A: 3D Printed Chassis
The faster path to a working cyberdeck. Start with existing designs or create custom parts.
Reference Designs
These existing projects provide good starting points for adaptation:
| Project | Platform | Description | Link |
|---|---|---|---|
| TypingCat Pocket Cyberdeck V2 | Thingiverse | Universal phone + Bluetooth keyboard clamshell. Arm-only and full-shell versions. | View |
| Mobile C-Deck | Hackaday.io | Modular smartphone cyberdeck with detailed build log and multiple iterations. | View |
| CMF Phone Cyberdeck | Printables | Clamshell design with magnetic attachment. Good reference for hinge mechanism. | View |
| T3rminal Build | Instructables | Full build guide with detailed assembly instructions. | View |
3D Print Settings
Recommended Print Settings
# General settings for structural parts Layer height: 0.2 mm Wall count: 4+ (for strength) Top/bottom: 4+ layers Infill: 20-40% (higher for stress points) Infill pattern: Gyroid or cubic # Hinge/stress areas Infill: 50-100% Wall count: 5+ Print orientation: Load across layers, not along # PLA temperature Nozzle: 200-210°C Bed: 60°C # PETG temperature (recommended for durability) Nozzle: 230-245°C Bed: 70-80°C
Materials Comparison
| Material | Pros | Cons |
|---|---|---|
| PLA | Easy to print, stiff, low warp | Brittle, low heat resistance |
| PETG | Tough, flexible, heat resistant | Stringing, needs tuning |
| ASA | UV stable, tough, outdoor-safe | Requires enclosure, fumes |
Option B: CNC Carved Wood Chassis
A premium build that trades quick iteration for durability and aesthetics. Real wood with proper laptop hinges creates something that feels like a genuine tool rather than a plastic prototype.
Why Wood?
Wood is warm to the touch, ages beautifully, and has excellent strength-to-weight ratio. A well-finished wooden cyberdeck looks professional rather than "maker project" — something you'd be comfortable using in a client meeting or café without drawing confused stares.
Design Concept
The wood chassis consists of two main shells connected by laptop hinges, with magnetic closures to keep it shut during transport:
wood_chassis_concept.txt
┌─────────────────────────────────────────────────────────────────────┐ │ CNC WOOD CHASSIS - EXPLODED VIEW │ ├─────────────────────────────────────────────────────────────────────┤ │ │ │ TOP SHELL (Phone Mount) │ │ ┌─────────────────────────────┐ │ │ │ ┌───────────────────────┐ │ ← Phone recess (pocket) │ │ │ │ │ │ Depth: 9mm │ │ │ │ Xperia 10 V │ │ Lip: 3mm │ │ │ │ Recess │ │ │ │ │ │ │ │ ← Cutout for USB-C at bottom │ │ │ └───────────────────────┘ │ │ │ │ ○ ○ │ ← Magnet pockets (corners) │ │ └──────────┬─────┬────────────┘ │ │ │ │ │ │ LAPTOP HINGES (×2) │ │ ├─ Torque: 0.3-0.5 Nm │ │ ├─ Opening: 0-135° │ │ └─ Screw mount to both shells │ │ │ │ │ │ ┌──────────┴─────┴────────────┐ │ │ │ ○ ○ │ ← Magnet pockets (matching) │ │ │ ┌───────────────────────┐ │ │ │ │ │ │ │ ← Keyboard recess │ │ │ │ 60% Keyboard │ │ Depth: keyboard height │ │ │ │ Recess │ │ + 2mm clearance │ │ │ │ │ │ │ │ │ └───────────────────────┘ │ ← Channel for USB cable │ │ │ [USB HUB POCKET] │ │ │ └─────────────────────────────┘ │ │ BOTTOM SHELL (Keyboard Mount) │ │ │ └─────────────────────────────────────────────────────────────────────┘
Wood Selection
| Wood Type | Properties | Recommendation |
|---|---|---|
| Walnut | Beautiful grain, medium hardness, machines well, dark colour | Excellent choice — premium look |
| Cherry | Warm reddish tone, ages to deeper colour, fine grain | Great choice — classic aesthetic |
| Maple | Very hard, light colour, clean look, durable | Good — modern/minimal aesthetic |
| Oak | Strong, prominent grain, traditional | Good — but grain may be busy |
| Beech | Hard, fine grain, light colour, affordable | Budget option — machines well |
| MDF | Consistent, cheap, no grain, takes paint | For prototyping only |
Stock Thickness
Start with 15-20mm thick stock for each shell. The CNC will pocket out the recesses, leaving ~6mm shell walls. Thinner stock risks weakness; thicker adds unnecessary weight.
Laptop Hinges
Proper laptop hinges provide the smooth, controlled movement that print-in-place hinges can't match. They're designed for thousands of cycles and hold position at any angle.
| Specification | Requirement | Notes |
|---|---|---|
| Type | Friction/torque hinge | Holds position without latch |
| Quantity | 2 (one each side) | Single centre hinge is less stable |
| Torque | 0.3 - 0.5 Nm | Strong enough to hold phone+case weight |
| Opening Angle | 0° - 135° | Minimum 110° for comfortable viewing |
| Mounting | Screw-mount flanges | M3 or M4 screws into wood |
| Size | ~30-50mm length | Match to chassis width |
Sources for laptop hinges:
- eBay/AliExpress — Search "laptop replacement hinge" or "friction hinge". Cheap but variable quality.
- Southco — Industrial supplier, high quality torque hinges. Search their E6 series.
- RS Components/Farnell — Industrial hinges, proper specs, UK stock.
- Salvage — Old broken laptops often have perfectly good hinges.
Magnetic Closures
Neodymium magnets embedded in the wood keep the clamshell closed during transport.
magnet_specification.txt
# Recommended magnets Type: Neodymium (N35 or N42) Shape: Disc Size: 10mm diameter × 3mm thick Quantity: 4 pairs (8 total) Placement: Corners of each shell # Installation 1. Drill/CNC pocket slightly larger than magnet 2. Test fit and mark polarity (N/S orientation) 3. Apply epoxy to pocket 4. Press magnet in, ensure flush or 0.5mm recessed 5. CRITICAL: Match polarity between shells! # Pull force calculation 10×3mm N42 magnet: ~2.5 kg pull force each 4 pairs total: ~10 kg combined Sufficient for: Secure closure + some drop protection # Alternative: countersunk magnets Type: Countersunk ring magnet Benefit: Screw through centre for extra security Size: 12mm OD, 4mm ID, 3mm thick
CNC Toolpath Strategy
cnc_operations.txt
# Stock preparation Material: Walnut/Cherry, 18mm thick Blank size: 320 × 180 mm (per shell) Fixturing: Double-sided tape + edge clamps # Operation 1: Profile rough (outline) Tool: 6mm flat end mill Stepdown: 4mm Speed: 18000 RPM Feed: 1500 mm/min Leave: 0.5mm for finish pass # Operation 2: Pocket rough (phone/keyboard recess) Tool: 6mm flat end mill Stepdown: 3mm Stepover: 40% Clear corners: Leave for smaller tool # Operation 3: Pocket finish Tool: 3mm flat end mill Stepdown: Full depth Stepover: 10% Purpose: Clean corners, smooth walls # Operation 4: Magnet pockets Tool: 10mm flat end mill (match magnet dia) Depth: 3.2mm (magnet + glue) Plunge: Helical or ramp entry # Operation 5: Hinge mounting holes Tool: 3mm drill or end mill Depth: 10mm (for M3 inserts) or through Pattern: Match hinge screw pattern # Operation 6: Cable channel Tool: 6mm ball end mill Depth: 8mm Path: Smooth curve from USB pocket to keyboard # Operation 7: Profile finish Tool: 6mm flat end mill Passes: Full depth, finish allowance Add: Chamfer or round-over on edges # Operation 8: Flip and face back (optional) Purpose: Reduce weight, add grip texture Tool: 6mm flat end mill Pattern: Shallow pockets or ribs
Detailed Dimensions for CNC
wood_chassis_dimensions.txt
# ================================================ # TOP SHELL (Phone Mount) - All dimensions in mm # ================================================ Overall length: 170.0 # Phone + margins Overall width: 85.0 # Phone + margins Stock thickness: 18.0 Wall thickness: 6.0 # After pocketing # Phone pocket Pocket length: 156.0 # Phone 155 + 1mm clearance Pocket width: 69.0 # Phone 68 + 1mm clearance Pocket depth: 9.0 # Phone 8.3 + screen protector Pocket corner radius: 5.0 # Match phone corners Lip height: 3.0 # Retaining edge # USB-C cutout (bottom edge of pocket) Cutout width: 15.0 Cutout depth: Full (through lip) Cutout position: Centre # Button clearance (right side of pocket) Cutout length: 45.0 # Cover vol+power buttons Cutout start: 40.0 # From top of pocket Cutout depth: Through lip # Magnet pockets (4 corners) Magnet diameter: 10.0 Pocket diameter: 10.2 # Slight clearance Pocket depth: 3.2 Inset from edges: 12.0 # Hinge mounting (back edge) Hinge spacing: 60.0 # Centre to centre Screw holes: Per hinge spec Recess for hinge body: As required # ================================================ # BOTTOM SHELL (Keyboard Mount) # ================================================ Overall length: 310.0 # 60% keyboard + margins Overall width: 120.0 # Keyboard + margins Stock thickness: 18.0 Wall thickness: 6.0 # Keyboard pocket (adjust to YOUR keyboard!) # Example: RK61 keyboard Pocket length: 295.0 # KB 293 + 2mm Pocket width: 104.0 # KB 102 + 2mm Pocket depth: 12.0 # KB height - want keys proud Pocket corner radius: 3.0 # USB hub pocket Position: Adjacent to keyboard pocket Size: As required for your hub Depth: To fit hub + cable # Cable channel Width: 12.0 Depth: 8.0 Path: Hub pocket → keyboard USB port # Magnet pockets (match top shell) Magnet diameter: 10.0 Pocket diameter: 10.2 Pocket depth: 3.2 Position: Align with top shell when closed # Hinge mounting (back edge, matches top shell) Hinge spacing: 60.0 Position: Centred on width
Finishing
A proper finish protects the wood and enhances the grain:
- Sand progressively — 120 → 180 → 240 → 320 grit
- Raise the grain — Wipe with damp cloth, let dry, sand 320 again
- Apply finish — Options below
- Between coats — Light sand with 400 grit, remove dust
- Final coat — Apply, let cure fully before assembly
| Finish Type | Properties | Application |
|---|---|---|
| Danish Oil | Penetrating, natural look, easy to apply, repairable | Wipe on, wipe off, 2-3 coats |
| Tung Oil | Durable, water resistant, food safe, matte finish | Thin coats, many layers, slow cure |
| Osmo Polyx | Hard wax oil, durable, natural feel, expensive | Thin coats, buff between |
| Lacquer | Very durable, glossy or matte, fast drying | Spray application, needs equipment |
| Shellac + Wax | Traditional, warm tone, easy repair | Pad/brush shellac, then paste wax |
Magnet Installation Timing
Install magnets AFTER finishing. Epoxy doesn't stick well to oiled/waxed surfaces. Either mask the magnet pockets before finishing, or lightly sand the pocket interior before gluing magnets.
Assembly Order
- Test fit all components (phone, keyboard, hub, hinges) in unfinished shells
- Make any adjustments to fit
- Sand and finish both shells
- Install threaded inserts for hinge screws (if using)
- Install magnets with correct polarity — TEST BEFORE GLUING
- Attach hinges to both shells
- Route and secure USB cable
- Final test of open/close action and component fit
Xperia 10 V Reference Dimensions
Critical measurements for either build approach:
xperia_10v_dimensions.txt
# Sony Xperia 10 V (XQ-DC54) Detailed Dimensions # All measurements in millimetres # Overall dimensions Width: 68.0 mm Height: 155.0 mm Depth: 8.3 mm # Screen Screen diagonal: 6.1" (154.9 mm) Aspect ratio: 21:9 # Button positions (right side, from top) Volume up: 45 mm from top Volume down: 58 mm from top Power/fingerprint: 75 mm from top Button protrusion: ~1.5 mm # Ports (bottom edge) USB-C: Centre, ~3.5 mm from bottom edge Audio jack: Left of centre, 3.5mm # Card slot (left side) SIM/SD slot: ~35 mm from top # Design clearances Add to width: +1.0 mm (0.5mm each side) Add to height: +1.0 mm Add to depth: +0.7 mm (screen protector)
CAD Resources
Tools for designing your chassis:
| Tool | Best For | Notes |
|---|---|---|
| Fusion 360 | Both 3D print and CNC | Free for personal use. Excellent CAM for CNC toolpaths. |
| FreeCAD | Both methods | FOSS alternative. Path workbench for CNC. |
| Carbide Create | CNC (2.5D) | Free, simple, good for basic pocketing operations. |
| VCarve | CNC | Paid but powerful. Excellent for wood projects. |
| OpenSCAD | 3D print | Parametric/code-based. Great for iterating dimensions. |