you’re here early!

welcome to the party. lemon’s portfolio page is currently a work in progress.

lemon.

because your desk isnt a sauna.

the anti small form factor small form factor pc.

practically every computer made since 1948 has the same problem. they utilize indoor air for cooling and exhaustion, creating a heating loop known as the sauna effect. lemon is a 13.5 liter small form factor micro atx chassis with an external, window mounted radiator, to prevent up to 90% of computer heat generation from ever entering your space.

practical skills

contributors

sheet metal design

metal cnc cam

hardware integration

design for manufacturing

cost optimization

lara goulart

chris lyons

lori resch

juan noguera

sam hao yu wang

generative ai disclosure.

google gemini was utilized in this project for:

worst. sauna. ever.

Between 2015 and 2025, peak CPU and GPU power consumption roughly tripled. A modern high-performance workstation under full load can pull upwards of 800W–1000W.

watts are watts. a 1000w gaming pc generates the same heat for your environment as a 1000w space heater. i went to forums and asked users how it affects them.

"i feel excluded to play anything but barebones games...lest I end up feeling like I have to try and sleep in a sauna."

the side effects.

in addition to the osha-defined hazardous levels of ambient temperatures. users reported additional side effects from being in an overheated room for extended periods of time. users reported it negatively affected their sleep, productivity, overall comfort, and stress level. other than that, everyone had headaches.

bye-bye, sweaty gamers.

utilizing a custom liquid cooling loop, lemon cools the hottest parts and exhausts the heat outdoors with an external, window mounted radiator enclosure.

smaller than smaller.

at 13.5 liters, lemon’s chassis is the world’s smallest micro atx chassis that fits a full size graphics card. this metric was reached by externalizing a lot of the cooling, but also without using a riser, a to-be-expected $100 markup on many small cases.

ready to go.

as a design for manufacturing (dfm) project, lemon was optimized for easy manufacturing, assembly, and cost-efficient in bulk.

a solution such as this is only successful if it can be reasonably acquired by the target market. lemon was made for the users, and should not just be expensive just because they’ll need it.

processwork.

  • the beginning.

    before i wanted to be a designer, i wanted to be an engineer, before that, an architect. before all of that, i was a gamer kid, who turned into the techie, building and fixing my first computer when i was 14.

  • the problem.

    this was my pc, vornado 1000W space heater. i’d been wanting to solve the overheating problem for years.

  • totally metal.

    i’d spent a lot of my time in school with wood, for my last year i wanted to explore an entirely new medium, which was either glass or metal.

  • think smaller.

    throughout my advertising immersion, there was one thing that primarily stuck: the volkswagen beetle lemon ads. a blunt, satirical, self-owning campaign that was so good, it’s taught as the greatest ad ever.

    the ad inspired the name, graphic design, and ethos.

  • there's an hvac problem.

    they look nasty. the radiator vice’s closest aesthetic and functional parallel is window mounted air conditioning units, which occupy windows, if not blocking them entirely.

    i wanted to allow users to keep their windows, designing lemon’s slim parallel vice to be minimally obtrusive.

  • there's access problems.

    the predecessor, the corsair 1000d is as small as it is due to a few sacrifices. one of the biggest sacrifices was port and i/o access. plugging in cables required turning the whole chasiss over. over time, small frustrations turn into bold new ideas.

  • the simplest solution...

    …is often the best solution. i worked on 2 major variations of my access hinge, but i landed at the same result. i was making the case physically larger for a solution designed to save space. instead of changing the motherboard layout, i left it in a traditional arrangement, and decided to shift where the “front” of the chassis was. no risers or complicated assembly, just easy access with minimal effort.

  • halfway, only starting.

    it’s hard to face an entire semester with honestly not that much to show in terms of my capstone, attention was primarily spent elsewhere. our class feeling behind, at least we were all on the same page in that way.

  • "i'll bend it myself!"

    one thing i’ve been told a lot through my time time at school is that i have an ambition to be reckoned with. one thing i didn’t realize is that i would be reckoning with myself. since the beginning, i had wanted to bend the chassis myself. it’d be good process, and i started making tooling for it.

  • "please don't."

    a good mentor will push you to fail on your own terms. a better one remembers to check the time and tell you when you’re a little out of your depth and very much out of time. i know you’ll be reading this, thanks Juan! i designed a chassis that would be nearly if not completely impossible to bend, so i started over using someone elses’s system, sendcutsend.

  • midterms.

    i went into midterms with a few certainties that needed to be nailed down: first and most importantly, which yellow lemon had to be (didn’t matter in the end), also which of my dial types were most sucessful for the window vice (which did matter).

  • a busy spring break.

    10 days. 3 projects. which one will make it? the one to show up on the portfolio first. welcome, you’re already here! i learned fusion sheet metal, integrated hardware, worked within constraints, designed packaging dielines and designed probably the most stressful glue up you’ll see this year. so much work, so little time.

  • bend direction matters.

    especially when you bend the whole chassis inside out. i could still salvage the clearances i needed for a chassis redesign, so it wasn’t all bad, and left a commemorative un-lemon chassis.

    my apartment isn’t messy, yours is the messy one.

  • lemon shavings.

    ever done cam before? its much easier when you have someone who knows every single drill bit by heart. mech-e’s. we love em. we need em. they have the good numbers.

    name (linkedin) and (name) ‘helped’ me out. please give them cool jobs.

  • pow! pow! powder!

    i initially planned a ceramic coating for lemon, but that was before my chassis was inverted amongst other things (there’s advantages to both! advantages! advantages!). i needed my silver lemon to turn yellow, and i needed it fast.

  • where the money flows.

    when lemon was assembled and all i needed to prepare was my final presentations, i noticed one major flaw with my entire goal of designing for manufacturing. the case was far too expensive and too niche to justify from a business standpoint.

  • the bad fruit.

    the case, the metro distribution system, the micro form factor, were all justifications for the one darling i couldn’t kill. the part that i had spent most of my energy and passion had to hit the reality of how production really works. the case stopped being viable and started being detrimental, so it was cut off.

  • the lemon.

    the radiator would be usable with any liquid cooled computer nearby any window, it cost significantly less to produce at at scale, with a competitive profit margin to the users who already have personal computers/space heaters, as an add-on product.

  • one mismatched fitting.

    despite everything, lemon made it to the exhibition in one piece. with one leak. it wasn’t running. after the exhibition, i found one mismatched fitting on the radiator.

  • 24 pages later...

    a process book was made! i’ll figure out some things to say about it!

  • putting rainboots on.

    it was time to put lemon to the test. before the weatherproofing i was terrfied to move it, let alone leaving it hanging out a window. i had IP67 fans, but the circuitry on board was still left to the elements.

    after printing louvres and meshes out of tpu for ams (yellow), it was finally time for testing.

  • look down (on the page)

    it’s getting sciency. scroll down to see the detailed results of: the lemon trials.

the lemon trials.

when i have good data for this, the section will be so cool. trust me guys.

the results.

this is gonna be like the section above this, but better… or just as good? find out later.

the copy.

while keeping my project under wraps, i followed the ddb design language in my

‘promotional materials’

think smaller - social media announcement/teaser.

six week proposal - capstone studio assignment.

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rùllu - 2025