01
Tent over tray
Two folded parts in 2 mm aluminium. The cover is the visible shell: rear lip, rear face, front face and front lip, with no bend reliefs, so every visible edge is a fold or a straight cut. The tray is a U whose triangular walls close the open ends from 0.5 mm inside. It takes all the reliefs and notches, where nobody looks.
02
Screen behind a window
The front face has a laser-cut window the size of the active area plus 0.75 mm a side. The display glass is bonded behind it with a 0.5 mm VHB frame, so the metal is the bezel. The glass's narrow 3.15 mm border goes up, towards the apex; the deeper 10 mm border carrying the panel's flex goes down.
03
60° screen, 60° back
The screen leans back 30° from vertical. The cover's bends are 120°, 120°, 120° from flat; the strictest published limit is 130°, so every fold is possible, but anything past 90° needs an acute punch. Ask the shop to confirm their tooling before ordering.
04
Fold order
A closed triangle cannot be folded from one sheet, so the cover is an open A. Fold both lips first, then the apex last. At the last fold the lip edges are 93 mm apart, enough for a narrow acute punch (35° or less) to reach in.
05
The stack
NVMe Base, Pi 5 with Active Cooler, then the DAC Pro on a riser, on one column of M2.5 standoffs screwed up through the floor. The stack slides front to back to balance its clearance against the display's back and the rear face: 10.7 mm to the display, 11.9 mm to the cover.
06
Air
Cool air comes in through 124 × Ø3 mm holes in the floor under the cooler, lifted 3.5 mm by the feet. Warm air leaves through 530 × Ø3 mm holes high on the rear face. The grille is a hex grid at 6 mm pitch: 3 mm webs, the strictest published minimum.
07
Rear I/O on one cut-out
Every port uses the Neutrik D-size cut-out: Ø24 mm with two Ø3.2 mm screw holes on a 19 × 24 mm diagonal. Any D-series insert drops into any hole, so the I/O can change without recutting the metal.
08
Volume on the side
A Bourns PEC11R push-button encoder goes through a Ø7.5 mm hole in the right-hand tray wall. Its Ø29.6 mm aluminium knob is centred in the side view, 27 mm clear of the outline on all three sides, and stands 28 mm off the wall: the product is 349 mm wide over the knob. Turn for volume, press to pause. The DAC Pro sets GPIO 23 and 24 aside for a volume encoder and GPIO 27 for its switch, and the Pi stack sits 26 mm in from the wall so the encoder's wires have room behind it.
09
Fixings you don't see
Six M3 countersunk screws come up through the floor into PEM CLS-M3-1 clinch nuts pressed into the cover's lips. Lift the product and the screws are there; look at it on a desk and the shell is unbroken.
10
Files for the shop
Material 2 mm 5052 or 5251, inside radius 2 mm, K-factor 0.40 (an estimate: the shop's own value wins). Send the formed STEP and let the shop unfold it with its own tooling. The DXF flats are for checking and for laser-only quotes.