Magnetic PSU Dust-Filter Frame

Design a detachable magnetic dust-filter enclosure for the rear exhaust of an older desktop PC power supply (SMPS). Overall design: - Create a rectangular external filter frame that mounts around the SMPS exhaust area. - The frame must be detachable from the PC cabinet. - Use four neodymium magnets for attachment. - The filter must NOT directly touch or cover the SMPS exhaust fan. - Maintain a 20 mm air gap between the SMPS exhaust grille and the dust-filter mesh. - The exhaust airflow must remain unrestricted through the entire chamber. DIMENSIONS: Main filter frame: - Outer width: 160 mm - Outer height: 160 mm - Frame thickness: 5 mm - Frame border width: 15 mm Air chamber: - Internal depth: 20 mm - Internal width: 130 mm - Internal height: 130 mm Dust-filter mesh: - Width: 130 mm - Height: 130 mm - Thickness: 1 mm - Mount the mesh on the outer face of the frame. - Mesh should be removable for cleaning. Magnet mounting: - 4 cylindrical neodymium magnet pockets. - Magnet diameter: 8 mm - Magnet thickness: 3 mm - Magnet pockets positioned near the four corners. - Center of each magnet should be 10 mm from the outer edges. - Magnet pockets should be blind holes, 3.2 mm deep. - Magnets must be flush with the rear mounting surface. Mounting frame: - Provide four mounting contact points corresponding to the magnets. - Use a 1 mm rubber gasket around the mounting perimeter to prevent vibration and unwanted dust bypass. - Do not seal the SMPS exhaust opening itself. Airflow: - Create a completely open central airflow passage. - No internal baffles. - No fine filter directly against the SMPS exhaust. - Keep the entire 130 × 130 mm central passage unobstructed. - The filter mesh should be coarse enough to minimize airflow restriction. Geometry: - Use rounded external corners with a 3 mm radius. - Use 2 mm fillets on exposed edges. - Keep the frame lightweight and suitable for 3D printing. - Design all parts as separate printable components: 1. Main magnetic frame 2. Removable mesh retaining ring 3. Four magnet inserts/caps 4. Rubber gasket Manufacturing: - Intended for FDM 3D printing. - Recommended wall thickness: 2.5 mm. - Recommended layer-friendly geometry. - No supports should be required where possible. - Provide assembly clearance of 0.2 mm for removable components. Output: - Generate a fully parametric 3D CAD model. - Include all dimensions. - Make the mesh a separate component rather than modelling the individual mesh openings. - Add labels/dimension references for the 160 × 160 mm outer frame, 130 × 130 mm airflow opening, 20 mm air gap, and 8 × 3 mm magnet pockets.

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