CubeSatLego

The case is using Aluminum as it's material and has weighing 0.2kg. To reduce part quantity, I design it to be 6 parts, 4 side walls, 2 caps, and 4-M3 socket bolts at each top and bottom wall (1U). Each side wall is typical, they're connected each other using slots at the rail. If you want to make 2U or 3U, you can use MidWall and connect it to holes at bottom and top side of rail of side wall, and tighten the connection using set screws. The wall thickness is 1mm. Mounting holes at each sides are 4mm diameter. Bottom and Top Cap also typical. The Caps and MidWalls has lock mechanism, so it could help reduces the screw quantity. As for Al material, I think it's better to use Direct Metal Laser Sintering for fabrication, as it doesn't have too many difficult geometry.