Quartz 5

Design

3 min read

Index
I want to start documenting the design process. I know that for this to work I must implement a unibody design that follows real machining constraints and preferably not just idealised CAD shape that will never work (architecture). I want to mimic the M1/M3 MacBook machining philosophy as closely as I can, but the Motherboard I am building around (Framework 16 Mainboard) changes a lot of the assumptions Apple gets to make.

Unibody Design

Instead of using stamped metal sheet shells with an internal skeleton bolted together has been proven to be obsolete in comparison to unibody design in the manufacturing of laptop chassis.

CAD designing process

Modelling process:

Thanks to the open source nature of Framework, the 3D CAD files, 2D drawings and schematics (for the motherboard and even the shells and body of the laptop) are stored on a Github repository that is under a free to use and modify license. This simplifies the designing and modelling process significantly as it negates the researching and measuring step.

  1. Freeze the motherboard:

    1. Measure: (due to the open source folders, most of these tasks have become obsolete however the ones highlighted are still necessary to do)
      • Motherboard outline
      • Mounting hole locations
      • Height of every connector or extrusion (USB port, HDMI port, SSD thickness, heatsinks, RAM)
      • CPU fans and cooling system heights and dimensions
      • Battery connector, display connector and speaker connectors etc.

  2. Decide outside shape:

    1. Before adding any internal features, I must decide on:
      • Overall length
      • Width
      • Thickness
      • Corner radius
      • Side profile
      • Keyboard position
      • Trackpad position
      • Display hinge location

  3. Place the motherboard onto the shell via an assembly:

    1. I must however leave room for the such components:
      • Battery
      • Speakers
      • Cooling
      • SSD
      • Fans
      • Cables
      • Antennas

  4. Add motherboard standoffs:

    1. Instead of simply drilling holes, create standoffs. A standoff is: a cylinder with a screw hole that lifts the motherboard above the bottom surface as mentioned in Safety.
    2. Typical dimensions: Height: 3–8 mm Diameter: 5–8 mm Screw hole sized for your fastener These prevent the PCB from bending.

  5. Add ribs to the :

    1. a

After the motherboard is mounted and the ribs are in place, you can begin adding the remaining structural and functional features. Design screw bosses wherever the top and bottom halves of the enclosure will be fastened together, ensuring each boss is reinforced with ribs and provides enough clearance for a screwdriver during assembly. Next, create internal walls and partitions around components such as the battery, speakers, fans, and SSD to keep them securely positioned and prevent movement. Every internal component should have a dedicated mounting method, whether that is screws, clips, brackets, or adhesive surfaces, depending on the part and how it will be serviced. As the internal layout takes shape, plan the airflow path by providing unobstructed intake and exhaust vents and ensuring that ribs or other features do not block the movement of air through the cooling system. Large flat areas of the enclosure should then be reinforced with additional ribs or box-like structures to improve stiffness without unnecessarily increasing wall thickness. Before considering the design complete, perform a thorough clearance check to confirm that the motherboard, connectors, cables, fan, battery, and all other components fit correctly without interference and that ports align accurately with the openings in the enclosure. Finally, manufacture a prototype—typically through 3D printing—to test the overall fit, assembly process, and structural integrity. It is common to iterate through several prototype revisions, making adjustments to dimensions and mounting features before arriving at a final design suitable for production.

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