Arris DOCSIS - Cable modem - 1RU rack mount

Summary

I've got a small networking rack, where my router and switch are located. I've also got an NBN HFC modem, (a DOCSIS cable modem), this is produced by Arris for NBN Australia, but their enclosure is used across many different product lines.

The 3d print snaps onto the top and bottom of the modem, and with some screws, and a rack blank plate makes for a robust rack mount for the unit.

Parts Required

• 1x 3d prints for Top/Bottom Mounts
• 4x M3x8mm Socket Head Cap screws
• 6x M3x8mm Flat Head Hex screws
• 10x M3 nut
• 1x 1RU blank plate: Pulse RPP1 (~$4AU Element14: 3371439)

Assembly Instructions

• Print Top/Bottom 3d-printed parts
• Perform test-fit on modem, parts slide into the front, and then lock at the back
• Drill + Countersink 6 holes in the 1RU blank plate, be careful not to drill through!
• Install M3 nuts in 3d print, helps to use a very-small dab of glue
• Clip parts to modem, install M3 screws in the back to lock mounts to the modem
• Install flat head screws through the 1RU plate.
• Install into rack

Printing Tips

I used a 0.35mm profile with a 0.4mm nozzle. Since these are largeish parts.

To get the best possible hexagonal pattern on the base of the prints, I adjusted prusaslicer extrusion width for the first layer near 0.6mm, until the hexagons didn't have lots of little tiny fills of extrusion. They'll look nicer if they're made up of single extrusion lines.

I increased the bridge flow rate on the 2nd layer with a height based custom modifier. I found a value of 1.4-1.6 worked nicely from the default 0.95.

Remix Ideas

• Light-pipes for status LEDs
• Extra spot on rack mounted plate for keystone RJ45 jack
• Fan for modem