Raspberry Pi 5 test print for billet aluminum case

Screws paid link (https://amzn.to/3OkCwHL)

This is a test print / fit-check prototype for an upcoming premium billet aluminum case for the Raspberry Pi 5 (designed for the 8GB version, with easy adaptation for 4GB via thermal pad shim).Use this 3D printable version to verify fit, port alignment, tolerances, thermal pad / heatsink placement, screw holes, and overall ergonomics before committing to CNC machining the final aluminum enclosure. Many high-end Pi 5 aluminum cases start life exactly like this—3D printed proofs that save time and material.Why this test print exists
I’m developing a sleek, durable, passive-cooled (or fan-optional) billet 6061 aluminum case with precise cutouts, excellent heat dissipation via integrated thermal contact points, and a premium machined finish. This prototype lets the community test the design early, provide feedback on real-world tolerances (shrinkage, layer lines affecting fit, etc.), and help refine the final machined version.Key Features of this Test Print

• Exact 1:1 scale replica of the planned aluminum case internals and externals
• Precise cutouts for all Pi 5 ports: dual HDMI, USB 3×2, USB-C power, Gigabit Ethernet, PCIe FFC slot, microSD, GPIO access
• Openings for official/active cooler or custom heatsink pillars
• Mounting points for M2.5 screws (paid link https://amzn.to/3OkCwHL)
• Clearance checks for RAM/SoC height differences (8GB vs 4GB)
• Optional top vent slots for airflow testing
• Easy snap-fit or screw-together assembly (print top/bottom separately)

Printing Recommendations

• Printer: Bambu Lab X1C / P1S / A1 series (or any FDM printer with good dimensional accuracy)
• Material: PLA or PETG (for better durability during repeated test fits); ABS/ASA if you want closer thermal expansion match to aluminum
• Layer height: 0.20 mm (0.16 mm for tighter tolerances on critical fit areas)
• Infill: 15–25% grid
• Walls: 3–4 perimeters (1.2–1.6 mm wall thickness)
• Supports: None 
• Tolerances tip: Print a small calibration cube first if your printer is not dialed in; most users find 0.1–0.15 mm horizontal expansion compensation works well for snug Pi board fit.
• Print time: ~1-1.5 hours depending on settings and printer