Mini Rack Home Lab 2020 Aluminum Extrusion

This is a 7-inch mini rack system designed around 2020 aluminum extrusion.

The design is inspired by (remixed from) https://www.thingiverse.com/thing:4612800, but has been adapted specifically for 2020 profiles rather than 1-inch or 2525 extrusion. Several components were redesigned to improve compatibility and usability. In particular, the switch mount and patch panel were reworked while maintaining the original concept, resulting in a cohesive and well-aligned system.

All components in this build were printed in ASA due to its superior thermal resistance and structural stability. Initial tests using PLA+ (based on the original design by Cruckman4) showed minor deformation and sagging over time under heat. However, these effects were minimal and can be mitigated with proper assembly, such as re-tightening screws and ensuring secure mounting. As a result, PLA+ should work depending on the use case and environment.

This project is part of my ongoing learning process in CAD design. Currently, I have only developed trays and enclosures for devices I own, as those allowed for precise measurements. If there is interest in additional device support please let me know.

Below is the list of links of items I used for this build, no affiliation in any links provided.

1 x 2020 Aluminum Extrusion T-Slot 300mm https://www.amazon.com/dp/B0DY7GSJZP?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_1&th=1

1 x 25pc 1/4-20 x 1/2" Button Head Socket Cap Bolts https://www.amazon.com/dp/B07FR85BY3?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

2 x M4x5x6mm 50pcs heat set inserts https://www.amazon.com/dp/B0CTCT5TXZ?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

1 x m4x12mm washers stainless steel 100pcs https://www.amazon.com/dp/B07KP4KQ5M?ref=ppx_yo2ov_dt_b_fed_asin_title

2 x M4 x 8mm 300PCS Button Head Hex Socket Cap Screws stainless steel 300pcs https://www.amazon.com/dp/B0FY5QDW6K?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

Until this point I've only used the items in the link provided but keep in mind is a work in progress so I might add things as use in the future.