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FormD T1 AIO Cover - Everything about the Tophat Mod!

FormD T1 AiO with 3D printed AiO cover

The FormD T1 is probably the PC case with the largest fan base in the SFF segment. It is not for nothing that there are dozens of builds in the corresponding subreddits and even dedicated Discord servers on which fans indulge their passion for this case. My enthusiasm for the FormD T1 has now flared up too, but it wasn't always like this...


At the beginning, I was bothered by the fact that a 240mm AiO (all in one water cooler) only fits into the case with a certain fan configuration. A 15mm slim fan has to be used, which significantly reduces the cooling performance - at least in theory. I decided to equip my Ncase T1 V2.5 with an AiO anyway and live with this compromise. But somehow I always wanted to know: what I was missing out on? How marginal or perhaps huge might the performance or noise improvements be if I manage to use two full-size 120mm fans with the AiO?


FormD offers an AiO cover on their homepage in the "DLC" category. I had already seen this modification from Chris Russell and was therefore familiar with it. It is an STL file that can be printed out with a 3D printer or (by the professionals) made with a CNC milling machine, adding up to 16mm of additional space to the lid of the case. Enough to accommodate a standard 27mm radiator + two Phanteks T30. What? OK, now my interest has been piqued.


Let me take you on this journey. The result may surprise you!



My current build - this is the hardware

Case

Ncase T1 2.5 (2.5-slot mode)

CPU

Ryzen 7800X3D @ 76.7W | CO -20

CPU Cooler

EK Nucleus CR240 AiO, pump@1550rpm

AiO Fan 1

Thermalright TL-B12

AiO Fan 2 (Slim)

Noctua NF-A12x14 PWM Chromax

Graphics Card

Nvidia RTX 4070 Super FE

Motherboard

AsRock B650I Lightning WiFi

Power Supply Unit

Corsair SF750

It actually looks pretty good, doesn't it? A mid-tier gaming PC with decent cooling, you might say. Let's take a look at how we can make the case compatible with the AiO with two Phanteks T30 using the DLC from FormD linked above.



Creativity is required - especially in 3D printing


Let's first look at what we're dealing with. So we download the file and put it into the slicer, the software that turns the 3D model into a series of commands for the 3D printer. It's clear: we have a problem!

FormD T1 AiO cover in Orca Slicer Screenshot

The top cover doesn't quite fit on the print bed of my Bambu Lab P1S with its 256x256x256mm. At 337.5mm it is unfortunately much too long. I remembered a chat I recently had with EIGA , who told me how someone printed his FormD T1 Exhaust Shroud at a 45° angle with tree supports.


So I quickly modified the AiO cover a little, aligned it at a 45° angle and added tree supports. In this video, Slant 3D shows how this can work in an even more material-saving way. I didn't care about the material savings at first, as I wanted to check whether anyone could print the same model using only tree supports, even without customising it.

successfully printed FormD T1 AiO Cover with Tree supports

I think the result is impressive! When I tried to mount it, however, I noticed that the rear attachment points did not fit into the existing recesses in the housing. Neither on the 2.1 nor on the 2.5.


I made a temporary solution by using a side cutter.

FormD T1 V2.1 back panel with AiO Cover, doesn't fit
FormD T1 V2.1 back panel

Since it doesn't look particularly nice and doesn't hold up very well, I adjusted the 3D file again and made it suitable for both the FormD T1 V2.1 and the Ncase T1 V2.5. Yes, I know, it didn't turn out particularly nice, but it works!


Please don't let the poor cooling on the slope put you off. I printed the file with too little cooling and too high a speed. With this 22mm test piece, I just wanted to check whether the panel could be pushed in and screwed in, and it works perfectly!


I then implemented the other Slant 3D optimizations already mentioned above, which save a lot of material. About 130g of filament and almost 6 hours less printing time are on the clock!

FormD T1 AiO Cover 3D printed

You can download the customized file on my Printables . I have also included the G-code for printing there, so that any Bambu Lab P1P, P1S or X1C owner can easily adapt it.



The FormD T1 AiO Cover in the temperature test


Now that we have successfully installed the part, let's take a look at what the extra space in the lid does for cooling. In the first attempt, I installed the EK FTP fans instead of the Noctua NF-A12x15 Chromax and Thermalright TL-B12, the stock fans of the EK Nucleus. During installation, I noticed that the fans are not exactly premium quality. The Thermalright TL-B12 and the Noctua NF-A12x15 PWM Chromax somehow felt more valuable. Let's see what the parts can do.

FormD T1 AiO Cover Temperatures EK fans vs. Noctua diagram
FormD T1 AiO Cover Noise EK fans vs. Noctua diagram

The result is not really convincing either. The duo of EK FTP fans can position themselves almost 3 degrees better at low speeds, but even at 680 rpm, the minimum speed, which is 80 rpm more than the Noctua-Thermalright combo. This also means that the EK fans are above the background noise of 28 dB(A) in my quiet work room, even at just 680 rpm, and are therefore clearly audible.


At 1000 rpm, the unlikely pair of Noctua and Thermalright suddenly catch up with the EK fans and are already within the error tolerance range at just 0.3°C. My guess is that the Noctua NF-A12x15 couldn't really work at 600 rpm, but can now do so much better at 1000 rpm. The operating noise is now also at exactly the same level as the EK fans.


If we look at the values at maximum speed, it becomes clear that the Noctua-Thermalright combo is clearly superior. At the same temperature, the Noctua and the Thermalright rotate at just 1850 and 2000 rpm respectively, while the EK FTP fans rotate at 2400 rpm each. This is also reflected in the noise levels. The EK fans are extremely loud at 54 dB(A), making the Noctua and Thermalright pair seem almost pleasantly quiet at 47.5 dB(A).


So much for the first results against the underwhelming stock fans from EK. But what we are really interested in is how the Phanteks T30 performs on the AiO, for which there is now enough space thanks to the AiO cover. Let's take a look at all the values in detail.

FormD T1 AiO Cover Temperatures Phanteks T30 fans vs. Noctua diagram
FormD T1 AiO Cover noisePhanteks T30 fans vs. Noctua diagram

The Phanteks T30 live up to their reputation. At 600 rpm they reach CPU temperatures on the radiator that are 4.5°C lower than the Noctua+Thermalright and still 1.6°C lower than the EK FTP fans. However, they are inaudibly quiet and also remain below 28 dB(A), the background noise in my office.


Even at 1000 rpm, the T30 fans can set themselves apart from the EK fans by 1.6°C and from the Noctuaright combination by 1.9°C. Like the other two options, they reach exactly 31.5 dB(A) and are audible but not unpleasantly loud.


At maximum speed of 2000 rpm, the Phanteks T30 manages to maintain its lead of 1.9°C and 2°C respectively. However, the only weakness of the T30 becomes apparent here: they are not the quietest at high speeds and have to admit defeat to the Thermalright and, admittedly, slower rotating Noctua in terms of noise.



The FormD T1 AiO Cover - My Conclusion


Who benefits from the FormD T1 AIO cover? So far I have seen few builds that use the AiO cover. This may be because it is not that easy to print without modifications. An SLS printed version from a reputable supplier here in Germany costs just under €200! Especially considering that the cover did not fit in its original version - I remember the side cutters - this price is of course steep. If you also consider that the complete case is also available in roughly this price range, this does not make the AiO cover any more attractive.


With the remix I created using the simplest of means and the pre-sliced G-code, the cover can now be printed in one piece by anyone who owns a 3D printer with a build space of at least 256x256x256mm! The material costs are around €6 to €12. Nothing has gone wrong with my two prints so far. This means that the add-on part is definitely in an area that will be quite interesting. Especially when you look at what can be achieved with two Phanteks T30 fans in terms of CPU temperatures.


Personally, I found it to be a super interesting project from which I was once again able to learn something.


What do you think of the AiO cover?

Do you or a friend have a 3D printer and want to try printing?


Feel free to leave me a comment!

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