Building the Smallest PC Possible
I recently discovered a super tiny RTX 4060 GPU from Gigabyte, which sparked my curiosity to build the most space-efficient PC I could imagine, but I soon faced unexpected challenges that tested my design skills and patience.
This journey pushed me to optimize every component, leading to a compact build that nearly melted under load, yet ultimately proved that with the right tweaks, even the smallest setups can deliver impressive performance.
TL;DR
I found a compact RTX 4060 and searched for the tiniest case, realizing I needed to create one myself for true efficiency.
Gathered smallest components like a low-profile motherboard and power supply, then designed a 3D-printed frame to minimize space.
During testing, the PLA plastic case started melting from heat, forcing quick material changes to avoid disaster.
Switched to ABS plastic and added ventilation, allowing the build to run games smoothly without further issues.
Ended with a functional 3.6L mini PC that exceeded expectations, inspiring future improvements for home printing.
When I first laid eyes on the RTX 4060 from Gigabyte, I was intrigued by its small size, even though I knew its price-to-performance ratio wasn't ideal for most builds. I wanted to pair it with the most compact setup possible, so I started by looking at existing cases like the Louqe 3D HT5 and Velka 3, but none felt quite right—they were still larger than necessary, leaving unused space.
To make this truly efficient, I decided to design my own case, beginning with the largest components like the ITX motherboard, which all share the same standard size. I chose one with low-profile heat sinks to fit an Intel Core i5 13400F under gaming loads, and for cooling, I opted for the 47mm tall Alpenföhn Black Ridge cooler, knowing smaller options existed but this one balanced size and performance well.
The power supply was the trickiest part; I considered SFX units but ultimately went with an even smaller HDplex all-in-one ATX model, rated at just 250 watts and passively cooled without a fan. This choice saved significant space, as it didn't require an external brick, and I figured it would handle the GPU's 115 watts and the CPU's 65 watts without issues, at least in theory.
With all parts selected, I created rough 3D models to visualize the layout, orienting the GPU directly into the motherboard and positioning the power supply efficiently. My initial design came in at 3.7 liters, but by rearranging—moving the power supply above the board and using a riser cable for a vertical GPU—I reduced it to 3.5 liters, and then down to 2.7 liters by swapping to a shorter 37mm Noctua L9 cooler.
I printed the case frame in two pieces due to my 3D printer's limitations, adding screw points for assembly. The first attempt had errors, like incorrect measurements, but after revisions, I had a solid frame that secured the motherboard, power supply, and GPU tightly.
The side panels were inspired by classic compact cases like the Silverstone SG13, incorporating aesthetic cutouts for a clean look. Once assembled, the build looked promising, but when I tested it with Overwatch 2 at 1440p and 240Hz, disaster struck—the PLA plastic began to deform and melt from the heat, which I hadn't anticipated despite the GPU's modest 100-watt TDP.
Realizing PLA softens at around 60 degrees Celsius, I switched to ABS filament with a higher tolerance of about 100 degrees and added ventilation at the top to improve airflow. This fix worked wonders; temperatures stabilized in the mid-70s for both the CPU and GPU, and the power supply handled the load without problems.
Though the panel fitment needed tweaks for better support in plastic, the final 3.6-liter PC ran smoothly, turning my vision into reality. I even added a custom power switch from a mechanical key for a retro touch, making the build feel personal and functional.
This project taught me valuable lessons about material choices and thermal management in compact designs, leaving me eager to refine the 3D files for others to try at home.
As I reflect on this build, I'm excited about the potential for even smaller, more efficient PCs in the future, especially with advancements in cooling and printing materials.
Key Takeaways
Compact GPUs like the RTX 4060 enable innovative small builds, but require careful component selection for space efficiency.
3D printing a custom case allows for optimized layouts, though material like PLA can fail under heat, making ABS a better choice.
Adding ventilation is crucial in tiny PCs to prevent overheating and ensure long-term stability during gaming.
Performance in a 3.6L build can match larger setups, running demanding games at high resolutions and frame rates.
