BC-250 + Flex PSU PC Steam Console Case - A1 Mini

Update:

I've updated the model to tighten some tolerances and I've moved the 16mm button hole into the grill (either front or side) so the location can be in up to 5 different positions (depending on the button and fans used the front position might be tight).

BC-250 A1 Mini Case

A compact BC-250 case designed from the ground up to be fully printable on the Bambu Lab A1 Mini with fast print times and low filament usage compared to many existing BC-250 case designs.

The design focuses on:

• Full compatibility with the A1 Mini build volume
• Reduced print time
• Lower filament consumption
• Simple assembly with minimal hardware requirements
• Good airflow for media and light gaming workloads

Fan grills are not included. The photos show PC Fan Cover with Grille, Filter 60/80/92/120 by Gorilla Labs, but any standard 120mm fan grill can be used or printed according to your preference.

Current Status

This design is still a work in progress and should be considered a beta release.

I have personally been running this case continuously just over a week for:

• 4K movie streaming
• General desktop use
• Light gaming

During this testing, temperatures have remained in the low to mid 60°C range, even under peak loads. However, I have not yet subjected the system to extended heavy gaming or stress testing. As additional testing and revisions are completed, updates and improvements will be released.

Assembly Notes

Assembly is fairly straightforward overall.

The only challenging portion is installing the four internal heat-set inserts and screws that secure both the BC-250 board and the case structure together. Access is somewhat limited, along with your soldering iron a small pair of pliers or tweezers are recommended to make installation "easier".

Printing Recommendations

This model was designed and tested on a Bambu Lab A1 Mini using PETG-CF.
 

For best results:

• Clean the build plate thoroughly before printing large parts.
• Apply a thin layer of glue stick to the build plate before printing. PETG can bond very aggressively to PEI surfaces, and the glue acts as both an adhesion promoter and a release layer.
• Dry your filament before printing. PETG-CF prints significantly better when dry and will produce stronger parts with cleaner surfaces.
• Run bed leveling and vibration calibration if the printer has recently been moved or serviced.
• Allow parts to cool completely before removing them from the build plate.
• Avoid touching the print area of the build plate with your fingers immediately before printing.

The included print profiles contain the recommended print settings and were tested on an A1 Mini using PETG-CF, (I'll sometimes put a large box over the a1 mini when print PETG to reduce warping).