我把御三家主机合体了！

Project overview

The creator built a single 3-in-1 console named “Ningtendo PXBOX 5” that houses PS5, Xbox (Series S–style board), and Switch 2 motherboards inside one triangular-prism chassis. One button cycles between consoles; the three systems share a single HDMI output and a single power supply. The Switch 2 motherboard is removable via a small pop-up dock.

Project name: Ningtendo PXBOX 5

Design & engineering highlights

• Central cooling block inspired by the Mac Pro “trash can” internal cooler: a single center cooler with three contact faces and a fan on top that draws air up through the block.
• Single shared power supply: a 250 W GaN PC PSU chosen so only one console runs at a time (PS5 peak ≈225 W but ≈4 W standby). PS5 and Xbox motherboards accept 12 V DC and can be paralleled; Switch 2 requires a transformer plus a USB-C PD trigger.
• Lost‑PLA casting to make a custom aluminum cooler: 3D‑print a PLA positive, encase it in high‑temperature gypsum, burn out the PLA, and pour molten aluminum.
• Thermal interface: a pure copper buckle plate attached to the aluminum cooler; use thermal paste (not liquid metal) with the copper/aluminum stack.
• Switch 2 dock redesigned to be smaller and removable. The pop‑up mechanism uses 3D‑printed springs embedded in the case (PETG spring inside a PLA housing) printed on a dual‑extruder Bambu Lab H2D.
• An Arduino and a custom circuit handle console switching and LED indication (tri‑color LED shows the active console).

Step‑by‑step process (major steps)

1. Design the central cooler (triangular prism) with three motherboard contact faces.
2. 3D‑print the cooler positive in PLA; include reserved channels for aluminum flow and support structures.
3. Mix high‑temperature gypsum, vacuum‑degas (defoaming), and pour around the PLA model in a stainless bucket.
4. Burn out the PLA in a high‑temp kiln using a multi‑stage 12‑hour program (drying → pyrolysis → combustion → heat preservation).
5. Melt aluminum (Al melts ≈660°C); skim oxides and pour hot (≈700°C) into the preheated mold; cool and remove gypsum.
6. Remove the gate, machine/polish fins, attach the copper heat spreader, and mount motherboards and the fan beneath the cooler.
7. Route power: connect PS5 & Xbox 12 V rails in parallel, add a PD trigger for the Switch 2, and house the GaN PSU in a bottom compartment. Provide intake holes and a top fan.
8. Build the 3D‑printed pop‑up dock: platform, embedded spring, and L‑shaped USB‑C extension; iterate spring stiffness with printed variants.
9. Assemble the case, add walnut decorative panels, LED strips, the top button, and a metal nameplate.

Key problems encountered and solutions

• Casting failed initially because aluminum solidified before fully filling the mold. Fixes: raise pour temperature, preheat mold, reorient and thicken fins to improve flow.
• Gypsum mold walls cracked from thin walls and dense fins. Fix: increase wall thickness and change fin direction/density.
• Small air cavities (“meteorite craters”) appeared on one side — accepted because that side corresponds to the Switch 2, which needs less heavy cooling.
• Mechanical spring for the pop‑up was too weak when using metal springs. Fix: switch to 3D‑printed PETG springs integrated into a PLA housing for rapid iteration and correct force.

Performance & testing

• Thermal test: ran Elden Ring for 30 minutes with no overheating; measured surface temperature around 60°C in the test area — the cooler transferred heat effectively.
• Real‑world playtests: PS5 and Xbox games ran normally. Switch 2 exclusive (Donkey Kong) ran fine.
• Console switching worked with LED feedback: initial blue, press the triangle button → green (Xbox), press again → red (Switch 2); cycles among systems.

Practical tips & takeaways

• If sharing a PSU across consoles, confirm standby and runtime current draws and accept the limitation of running only one high‑load device at a time.
• For lost‑PLA casting: preheat the mold, vacuum‑degas the gypsum before setting, and control pouring temperature to avoid premature solidification.
• Use copper thermal spreaders when mating disparate materials (CPU die → copper → aluminum block) to improve heat distribution; thermal paste is adequate if you have good contact area.
• 3D‑printed functional springs (PETG inlaid in PLA) allow fast iteration and reduce mechanical assembly complexity.
• Keep intake/outlet airflow in mind: a central fan pulling upward over all three faces is efficient for a triangular arrangement.
• Expect iterations and failures—3D printing accelerates redesign versus hand‑sculpting wax.

Aesthetic & other notes

• The finished unit uses walnut decorative panels, an LED strip, a top triangle button, and a metal nameplate.
• The creator emphasizes the blend of ancient casting methods and modern 3D printing as a satisfying combination of craft and engineering.

Games, hardware & references

• Games: Elden Ring; Donkey Kong (referred to as “Donkey Kong Bananza” in subtitles).
• Hardware / products: PS5; Xbox (Series S–style board); Switch 2; Mac Pro “trash can” (inspiration); GaN power supply; Arduino; Bambu Lab MakerWorld; Bambu Lab H2D; PLA and PETG filament.
• Methods / references: lost‑PLA casting (lost‑wax style), high‑temperature gypsum mold, Yunwen Bronze Vessel (example of ancient lost‑wax casting). Cultural reference: Squid Game (brief).