The model I've printed, I use a filament change (M600) to make the top and bottom different colours. Multi-part model coming soon for people with dual extruders/MMU/Palette
Inspiration for the layout came from my favourite Pi 3b on here (https://www.thingiverse.com/thing:3714695), and the Pi 4 remix helped getting the ports lined up first time, so thanks for that.
For the GPIO to break out, make sure "Detect bridging perimeters" is unchecked in PrusaSlicer under Print Settings->Layers & Perimeters
You will need:
Tools - 2mm Allen Key, Phillips screwdriver (fan screws)
Screws for the fan openings:
For 30mm x 30mm x 10mm fan
For 40mm x 40mm x 10mm fan
(You can only fit a 10mm fan inside the case. For deeper fans, mount outside and adjust screw length to fit)
For the slim case with no fan opening and the 30mm case with fan mounted outside, Ive used a 25mm x 25mm x 10mm heatsink, it fits in there nicely. If you're going all out with cooling, in the 40mm fan case you could fit a 25mm x 25mm x 15mm heatsink only if you position it correctly so it doesnt hit the nuts holding the fan.
8mm rubber feet:
25mm x 25mm x 10mm heatsink:
25mm x 25mm x 15mm heatsink:
Im not affiliated to these sellers. Just some "cool" options :P
The holes for the screws and nuts might need a little clean up. When you place the M2.5 nuts in the bottom half of the case, screw the M2.5 bolt through the bottom half only until tight to help pull the nut in so its aligned properly.
For the GPIO to break out, make sure "Detect bridging perimeters" is unchecked in PrusaSlicer under Print Settings->Print Settings