Corsair Air 540 Modular SSD Enclosure System

The Corsair Air 540 case has been discontinued, and OEM SSD rack modules can be difficult to replace or source.

This modular SSD enclosure system is designed as a direct replacement and expansion solution for the original Corsair SSD mounting system. It also addresses Corsair part number CC-8930156 (Corsair Air 540 SSD cage Base with 4x SSD Tray), providing a functional replacement and upgrade path for users who have lost, damaged, or need additional SSD mounting capacity beyond the factory configuration.

This system integrates directly with the original Corsair SSD adapter system and requires no permanent modification to the case.

💾 Drive Compatibility

Supports standard 2.5" SATA SSDs and HDDs with the following thickness range:

✔ 6.5mm drives

✔ 7mm drives

✔ 9.5mm drives

✔ Up to 10mm drives

🧱 System Overview

This design consists of two modular components:

🔹 Corsair Base Enclosure

The Base Enclosure connects directly to the original Corsair SSD adapter that clips into the Air 540 case.

Precision friction-fit (zero tolerance design)

No modification required for standard use

Optional reinforcement via screw mounting points

Optional reinforcement:

Drill through tab locations using a 7/64” drill bit

Secure with M3 computer screws for maximum rigidity

🔹 Corsair Step Enclosure

The Step Enclosure is a stackable expansion module.

Connects directly into the Base or other Step modules

Zero-tolerance friction fit for tight mechanical coupling

Designed for unlimited stacking (within safe load limits)

Intended to remain assembled once inserted

⚠ As stack height increases, lateral load increases. For heavy storage arrays, reinforcement using M3 screws through tab points is recommended. Use black M3x8 screws for the perfect fit.

🖨 3D Printing Instructions

For best results, use strong and heat-resistant materials:

Recommended Filaments

PETG (recommended)

ABS

ASA or similar engineering-grade materials

Print Settings

Layer Height: 0.20 mm

Infill: 15% or higher

Supports: Required for all insert and tab geometry

Orientation: Print with tabs facing upward

🔧 Post-Processing Notes

Light sanding may improve friction fit consistency

Optional heat-set alignment for tighter tolerances (use caution)

Drill reinforcement holes only if permanent locking is desired

🔄 Modifications & Community Use

Modifications and remixes are encouraged.

If you remix or improve this design:

Credit the original author

Include a link back to this project page

💬 Support

If you have questions, encounter fitment issues, or need assistance with printing or assembly, I am happy to respond promptly and help troubleshoot or refine the design.