Modularity and minimalism - an unusual approach

[2timer]

Humor me for a spell, if you will gentlemen. I'm musing over the idea of building an unorthodox sort of SFF PC. I don't have a name for it yet, so tenatively I'll call it "the nucleus". The idea is a blend of a couple different principles. First, I'm trying to minimalize every component to as small as form as possible, while still retaining the performance characteristics I desire. For example, the motherboard size is mITX (the smallest FF that supports the desktop processors), the RAM is one 4GB stick instead of 2x2, and the HSF is slim or low profile.

Secondly, while aiming for minimalism as much as possible, I'm also attempting for a maximum of modularity. That is to say: ideally, every main component could be removed, disassembled, and (possibly) upgraded at a later point. The benefit of this approach is that by "modularizing," or isolating components into individual pieces, I can swap the pieces out arbitrarily, allowing for flexible and limitless customizing. I like this approach because I am very picky and I like having as much control as possible.

All this may sound complex at first, but in fact, the idea behind the execution is extremely simple. I want to have a "nucleus" consisting of motherboard, CPU and HSF, RAM, and case. The nucleus would be pretty tiny - about the size of a closed netbook. The physical footprint of the "nucleus" would remain pretty constant. It would basically be a case about 2" larger in perimeter than an mITX mobo, and just a couple inches high. Because mITX is such a popular FF, the "nucleus" case could be reused indefinitely in future iterations.

Around the nucleus would go the HDD, PSU, and more what I call "secondary" peripheals. I'm still undecided as to whether I want to go with a 2.5" HDD or mSATA FF, so let's leave that alone for now. The secondary peripheals would be stuff not important to the core of the PC, but stuff I'd like to experiment with. For example, things like a USB sound board, WiFi controllers/antennas, external HDs for media storage, eSATA enclosures, etc.

Now you're probably wondering "What the hell is the point of all this?" and rightfully so. I guess you could say I'm attempting to reconcile two seemingly different core ideas into one build: one, the idea of being minimalistic, and two, the idea of having a powerful and flexible PC. By making things modular, minimal, and removable, that allows me to have a tiny PC when I want, and have a versatile and powerful build of "nucleus" plus "peripheals" when I want. See what I mean? It's like two conflicting ideas, encapsulated within a singular design.

So that's basically the idea. If you have any feedback on this, or if you could help me describe what I'm trying to do more accurately, I'd appreciate it. I'm still needing some questions answered, but I figured it would be almost impossible to have those questions answered if I can't even explain what I want. Lol. So that's my idea. Whew, I'm exhausted now...

 

[AkumaX]

Check out the new thin-MiniITX standard

http://www.newegg.com/Product/Produc...82E16813128587

 

[dave_the_nerd]

So, you want a thin-miniITX, with a mSATA SSD and low-profile SO-DIMMs, an external power brick, onboard as-much-as-possible, and then you're attach additional stuff externally (eSATA HDDs, etc.) and build a custom case about the size of a J.K. Rowling novel?

Sounds a lot like an Antec ISK-100 to me.

 

[SithSolo1]

Buy a normal ITX motherboard for Intel CPUs and this case: http://www.mini-box.com/M350-universal-mini-itx-enclosure plus one of these PSU Kits: http://www.mini-box.com/Power-Supplies-Kits and a low-pro heatsink such as this: http://www.newegg.com/Product/Product.aspx?Item=N82E16835426028 (make sure it fits the board)


BAM! - "nucleus"

 

[2timer]

So, you want a thin-miniITX, with a mSATA SSD and low-profile SO-DIMMs, an external power brick, onboard as-much-as-possible, and then you're attach additional stuff externally (eSATA HDDs, etc.) and build a custom case about the size of a J.K. Rowling novel?

Sounds a lot like an Antec ISK-100 to me.

Yes! You are 90% on track! The mini ITX, external power brick, and SO-DIMMs offer me the perfect combination of size and performance, and cost is not prohibitive. The configuration you suggested is exactly 90% of the build I want to achieve.

So what about the other 10%, you may ask? Well, here's where factors of size, performance, and price become thornier. Hear me out for a second before you bag me.

Remember how I said I'm "picky," how I want to modularize components so that I can customize to get exactly what *I* want?

Here is the rub: I can get everything I'm looking for in a SFF PC *except* for the integrated GPU. I can go with AMD and get a premium IGP, but then the overall TDP is raised, and IPC performance lags behind.

Or I can go with Intel and get amazing TDP and processing performance, but the IGP is substandard for what I want.

So, until Intel offers an IGP that allows for respectable gaming at medium settings, or AMD gets their s**t together with TDP and IPC, then I have no choice except to go with a discrete GPU to meet my performance and budget demands.

The question I have been furiously mulling over, and the crux of the while problem itself, is this: how do I create a SFF PC wherein a discrete GPU is modular to the 'nucleus' I described?

USB sound boards allow for modular sound that can be plugged in and out. WiFi cards and external optical/hard drives too.

Essentially the only discrete element that isn't modular to my tiny nucleus is a discrete GPU. I have some ideas of how I could achieve the "modular" GPU, but it would require some modding. Do you have any ideas?

 

[SithSolo1]

Yes! You are 90% on track! The mini ITX, external power brick, and SO-DIMMs offer me the perfect combination of size and performance, and cost is not prohibitive. The configuration you suggested is exactly 90% of the build I want to achieve.

So what about the other 10%, you may ask? Well, here's where factors of size, performance, and price become thornier. Hear me out for a second before you bag me.

Remember how I said I'm "picky," how I want to modularize components so that I can customize to get exactly what *I* want?

Here is the rub: I can get everything I'm looking for in a SFF PC *except* for the integrated GPU. I can go with AMD and get a premium IGP, but then the overall TDP is raised, and IPC performance lags behind.

Or I can go with Intel and get amazing TDP and processing performance, but the IGP is substandard for what I want.

So, until Intel offers an IGP that allows for respectable gaming at medium settings, or AMD gets their s**t together with TDP and IPC, then I have no choice except to go with a discrete GPU to meet my performance and budget demands.

The question I have been furiously mulling over, and the crux of the while problem itself, is this: how do I create a SFF PC wherein a discrete GPU is modular to the 'nucleus' I described?

USB sound boards allow for modular sound that can be plugged in and out. WiFi cards and external optical/hard drives too.

Essentially the only discrete element that isn't modular to my tiny nucleus is a discrete GPU. I have some ideas of how I could achieve the "modular" GPU, but it would require some modding. Do you have any ideas?

Yeah...well thats the road block most people with similar ideas run into. There are no good or cost effective options for an external gpu.

 

[2timer]

Yeah...well thats the road block most people with similar ideas run into. There are no good or cost effective options for an external gpu.

Well that's heartening actually. Do you mean that the idea of an "external GPU" is actually legitimate? It would be great if just the premise was valid so I could be encouraged to explore solutions. But mainly when I breach the topic in other subforums I'm met with either : "Well why would you want to do that?" or "Just buy a bigger case."

People don't understand that I have no desire for even a large mITX case. I want my core components in a laptop sized enclosure and have my peripherals to plug in externally.

 

[Chime]

If you had the means of designing your own case, you could use a PCIe riser and have the port accessible through a removable cover on the side panel. You'd then need to create an attachable housing for the GPU that "docks" with the main case, with the PCIe connector of the GPU plugging into the exposed riser on the main case. You'd also need a power connector if you wanted to use a GPU that needed one. Which brings up the next problem: unless you want to fit an SFX psu into your main case, you're going to be limited by the power consumption of your GPU. I believe the highest wattage PicoPSU comes in at 200 watts.

 

[2timer]

If you had the means of designing your own case, you could use a PCIe riser and have the port accessible through a removable cover on the side panel. You'd then need to create an attachable housing for the GPU that "docks" with the main case, with the PCIe connector of the GPU plugging into the exposed riser on the main case. You'd also need a power connector if you wanted to use a GPU that needed one. Which brings up the next problem: unless you want to fit an SFX psu into your main case, you're going to be limited by the power consumption of your GPU. I believe the highest wattage PicoPSU comes in at 200 watts.

Interesting, very interesting. Now the creative juices are starting to flow!

I suppose, as a very rough outline, I could purchase a cheap fan less mITX case such as the M350 Universal, install a 90° PCI-E x16 riser on the motherboard, and use a router to drill a slot the size of an x16 bus on the side panel of the case. That would allow me to plug and unplug an external GPU into my "nucleus." And then I could upgrade or downgrade a discrete GPU without needing to change cases. See how that works?

I *think* that the hardest part of doing it this way would be designing an enclosure for the video card. Sure it would work "bare," but that's really not a good idea. I imagine I'd have to design a one-off enclosure though. I'm unaware of any commercial "graphic card enclosures."

It would be cool to design a GPU enclosure the same material and height as the case, to fit seamlessly on the side. That way, the GPU could be snapped on or off and it would look exactly like the case itself, only slightly enlarged. Kind of like putting Legos together.

You mentioned the power issue. Great point! Glad you noticed that. The highest Pico ATX PSU is 160w, so with a 45w TDP CPU that would give plenty of headroom for a discrete GPU. Or, with an 80w TDP CPU, I could pick a low power GPU. Lots of options!

See, to me at least, this idea is *much* better trying to build a mini ITX PC and being stuck with the weak selection of IGPs that Intel offers. I like having the ability to customize my parts exactly as I want.

 

[Chime]

If you were to wait for the new DirectCU mini from Asus you could use a second M350 to create your GPU case, as the DCU mini is the same length as a mITX motherboard.

 

[Gintaras]

http://www.engadget.com/2012/06/01/raspberry-pi-impressions-the-35-linux-computer-and-tinker-toy/

 

[2timer]

If you were to wait for the new DirectCU mini from Asus you could use a second M350 to create your GPU case, as the DCU mini is the same length as a mITX motherboard.

Hmmm, I will definitely look into that. Thanks for that suggestion!

 

[dave_the_nerd]

I have some ideas of how I could achieve the "modular" GPU, but it would require some modding. Do you have any ideas?

Thunderbolt. (Basically PCI-E x4.)

There are already external GPU/PCI-E enclosures available, they're just hideously expensive.

 

[VirtualLarry]

Well that's heartening actually. Do you mean that the idea of an "external GPU" is actually legitimate?

Get an Intel NUC, with a Thunderbolt port.

 

[2timer]

Hmm. That's two votes for Thunderbolt. And me being more current on Android, I'm afraid I don't even know what that is.

:hmm:

Time to hit Google

 

[2timer]

By Golly, it looks like the idea I had is already becoming a reality with Ultrabooks: http://www.anandtech.com/show/5352/msis-gus-ii-external-gpu-via-thunderbolt

Well I'll be damned, this Thunderbolt thing is almost what I was looking for to a tee. If only it was fully supported by the OEMs!

 

[Zap]

Here is the rub: I can get everything I'm looking for in a SFF PC *except* for the integrated GPU. I can go with AMD and get a premium IGP, but then the overall TDP is raised, and IPC performance lags behind.

Or I can go with Intel and get amazing TDP and processing performance, but the IGP is substandard for what I want.

So, until Intel offers an IGP that allows for respectable gaming at medium settings, or AMD gets their s**t together with TDP and IPC, then I have no choice except to go with a discrete GPU to meet my performance and budget demands.

What games? Can you please define your "medium settings" and "respectable gaming?"

I've gamed using Intel HD 3000, and was able to play "medium settings" (AKA "defaults") at 1366x768 resolution on my notebook. I think I played LoL and maybe L4D2 or something like that. LoL actually plays decently.

I just got a notebook with Intel HD 4000, which is supposedly at minimum 30% faster than HD 3000.
HD 4000 vs HD 3000

Next gen Intel is Haswell for socket 1150 maybe 3rd quarter 2013. It supposedly will have an even faster IGP that just about catches up to current gen AMD APUs, though of course AMD is upping the ante for their own next gen APU.

Also, check this out. :whiste: The Antec ISK 300-150 case is not super small, but may be close enough to your "case about 2" larger in perimeter than an mITX mobo." Dimensions of the case are:
96mm (H) x 222mm (W) x 328mm (D)
3.8" (H) x 8.7" (W) x 12.9" (D)
It can fit an ITX motherboard, three 80mm fans (one part of PSU), one optical drive, three 2.5" HDD/SSD (3rd one fits but no mounting holes), stock cooling and of course a low profile graphics card. Currently the highest end that fits inside this case and which can be powered by the included PSU is a Radeon 7750, which is much, much better than any current AMD APU. See this link. It is in French, but the graphs speak for themselves.

13.9FPS for Intel HD 4000
18.5FPS for the A10-5800K using IGP
42.4FPS for the A10-5800K using Radeon 7750

12FPS for Intel HD 4000
18.2FPS for the A10-5800K using IGP
48.5FPS for the A10-5800K using Radeon 7750

 

[2timer]

What games? Can you please define your "medium settings" and "respectable gaming?"

I've gamed using Intel HD 3000, and was able to play "medium settings" (AKA "defaults") at 1366x768 resolution on my notebook. I think I played LoL and maybe L4D2 or something like that. LoL actually plays decently.

I just got a notebook with Intel HD 4000, which is supposedly at minimum 30% faster than HD 3000.
HD 4000 vs HD 3000

Next gen Intel is Haswell for socket 1150 maybe 3rd quarter 2013. It supposedly will have an even faster IGP that just about catches up to current gen AMD APUs, though of course AMD is upping the ante for their own next gen APU.

Also, check this out. :whiste: The Antec ISK 300-150 case is not super small, but may be close enough to your "case about 2" larger in perimeter than an mITX mobo." Dimensions of the case are:
96mm (H) x 222mm (W) x 328mm (D)
3.8" (H) x 8.7" (W) x 12.9" (D)
It can fit an ITX motherboard, three 80mm fans (one part of PSU), one optical drive, three 2.5" HDD/SSD (3rd one fits but no mounting holes), stock cooling and of course a low profile graphics card. Currently the highest end that fits inside this case and which can be powered by the included PSU is a Radeon 7750, which is much, much better than any current AMD APU. See this link. It is in French, but the graphs speak for themselves.

13.9FPS for Intel HD 4000
18.5FPS for the A10-5800K using IGP
42.4FPS for the A10-5800K using Radeon 7750

12FPS for Intel HD 4000
18.2FPS for the A10-5800K using IGP
48.5FPS for the A10-5800K using Radeon 7750

Thanks man.

I know you're trying to be helpful so I won't spew my negativity on you. I'm guessing you missed this little diddy: http://forums.anandtech.com/showthread.php?t=2308805

I'm pretty sore with Intel about their HD Graphics lineup. Intel has 6 Ivy Bridge Pentium SKUs and 3 Celerons, yet only one IGP. They don't give you any choice. I assume this decision was made to create artificial demand for the Core processors. Problem is I don't need the overhead of a Core processor, so I would be paying Intel $120 for a processor that I only use at an 80% rate. And that SUCKS.

Regarding the performance, the HD 4000 looks playable on some games. And that's great for notebooks. For a desktop, however, there is no chance I am spending $200 for a processor. I'm sorry, I can't.

The ISK-300 is a great case for the mainstream, but it's too big for me. I'm picky. Why optical drive, for one? You carry that thing around with you, does it bother you that you have to carry a 3.5" optical drive? I use mine very infrequently. I don't see the need for one in a mITX case.

 

[Zap]

I'm guessing you missed this little diddy: http://forums.anandtech.com/showthread.php?t=2308805

I'm pretty sore with Intel about their HD Graphics lineup. Intel has 6 Ivy Bridge Pentium SKUs and 3 Celerons, yet only one IGP.

I did miss that (I'm not very active in CPU forum) but let me address some of the points brought up in your other thread to, ahem, temper your vitriol a bit.

How many Sandy Bridge Pentiums had HD 2000? Zero.

3D gaming performance is the same, as "HD Graphics" and "HD 2000" both have 6EUs. The difference is that HD Graphics does not have QuickSync, which does nothing for gaming.

I want low to average CPU performance with a solid IGP. Lol. AMD gives me that

As already pointed out in the other thread, not quite. For instance, what if you want A10 level graphics with a dual core? Whoops, no, AMD won't sell you one. To get the best A10 graphics, they require you to buy a quad core. You want to save money and get a dual core? Max you can get (currently) is an A6. So how well does it perform in games? Actually I don't know. AMD only sends out the better A8 and A10 to reviewers.

True you get a 20% increase, but so? For what games? Does the A10 make any game unplayable where the G860 + a 640 does?

See the images I posted previously. A10 is at under 20FPS for some current FPS games. For the vast majority of gamers, that is unplayable for an FPS, especially a multiplayer one like BF3. GT 640 does 31.3FPS in BF3. That is a world of difference from 18.5FPS, let alone 15.4FPS of an A8 and who knows what on a cheaper A6. Since you've emphatically state in the other thread, "I refuse to pay more than $100 for a CPU, period" (post #38) that means you are limited to a dual core AMD A6 APU.

A6-5400K has 192 shaders at 760MHz
A10-5800K/5700 has 384 shaders at 800MHz

Yeah, the A6 isn't going to perform anywhere close to the A10. The only way to get an A10 is with an A10-5700, which costs about the same as a Core i3-3225 with HD 3000. Granted it will outperform the HD 3000, but here's something else to consider: Power draw. See this thread. Intel CPUs typically draw less power than their TDP rating. AMD CPUs typically draw MORE power. This is independent of the IGP.

The ISK-300 is a great case for the mainstream, but it's too big for me. I'm picky. Why optical drive, for one? You carry that thing around with you, does it bother you that you have to carry a 3.5" optical drive?

Let me repeat what you said earlier in this thread.

case about 2" larger in perimeter than an mITX mobo.

And then the dimensions of this case.
3.8" (H) x 8.7" (W) x 12.9" (D)

Mini ITX motherboards are 6.7"x6.7" Your 2" larger in perimetere would put a case at 10.7"x10.7" or 114.49 square inches (not counting thickness). The Antec ISK 300 is 112.23 square inches (not counting thickness).

Assuming same thickness, then the Antec ISK 300 would actually be smaller in volume than your specified allowable size.

Something else to keep in mind is that all the smaller offerings such as the thin ITX mentioned earlier, or the Mini Box M350 case, or the Antec ISK 100/110 all use external power bricks. I would rather carry around a slightly larger case that has the PSU internally, than to have two separate pieces to carry around.

Also, smaller cases can't take an expansion card, which I wanted.

Regarding the optical drive, it is a slim unit. It barely takes up any space. I suppose they could have gotten rid of it, and then it could easily be made to hold two more 2.5" drives in that spot.

If I were to imagine my own perfect SFF computer case, the Antec ISK 300 is not it. Nothing currently on the market or AFAIK announced will meet my own personal desires for a SFF travel/LAN case. Will I complain to the world? No, I'd rather make my own. My vision for a case would be made of aluminum, bit smaller than the ISK 300, ditch the optical drive (you and I agree here :awe: ), still have internal PSU but more than 150W, still hold at least two 2.5" drives, still hold a low profile card, better ventilation.

Yes, I have an image in my mind. :whiste: In fact, I've been considering paying for a one-off case or making my own (I already have bending brakes, drill presses, riveting tools but need a better way to cut other than rotary tools). That S3 (linked above) apparently will cost $1500+shipping for Lian Li to make the first prototype. My idea is a lot simpler, so I can probably get it for under $1000 shipped.

But I digress.

I will make a prediction. You will NEVER get "best current IGP" in a low end CPU/APU. Intel doesn't give you their highest end IGP for under $100. AMD doesn't give you their highest end APU for under $100. (Unless overall prices of CPUs drop.) Your posts won't change this. What we (rest of us here) can do to help you is to suggest alternatives. Sure, they won't be exactly what you have imagined in your mind, but the alternatives are achievable.

Pick one:
1) Raise your CPU budget from $100 to $130. This gives you access to HD 3000 (and maybe more after Haswell comes out) as well as A10 APUs.
2) Use discrete graphics. This way you can use a cheap $40 Celeron and $60 graphics card, and hit your $100 target budget for CPU+graphics as well as your desire for low end CPU + highest end performance relative to the best IGP.
3) Lower graphics performance requirements.
4) Wait a year or two before buying, and accept that you still don't have the then current best IGP but will have the IGP performance of when you started on this journey in early 2013.

 

[Zap]

Wow, WTF? I didn't intend to go that long.

tl;dr You won't get what you want, for various reasons. Let us suggest alternatives.

 

[AkumaX]

i3-3225 w/ HD4000 for $120?

 

[Zap]

i3-3225 w/ HD4000 for $120?

Micro Center's normal everyday low price. If you buy it with a motherboard (and they WILL pricematch Newegg on mobo pricing) they will knock an additional $40 off, making the CPU $80.

 

[2timer]

I will make a prediction. You will NEVER get "best current IGP" in a low end CPU/APU. Intel doesn't give you their highest end IGP for under $100. AMD doesn't give you their highest end APU for under $100. (Unless overall prices of CPUs drop.) Your posts won't change this. What we (rest of us here) can do to help you is to suggest alternatives. Sure, they won't be exactly what you have imagined in your mind, but the alternatives are achievable.

Pick one:
1) Raise your CPU budget from $100 to $130. This gives you access to HD 3000 (and maybe more after Haswell comes out) as well as A10 APUs.
2) Use discrete graphics. This way you can use a cheap $40 Celeron and $60 graphics card, and hit your $100 target budget for CPU+graphics as well as your desire for low end CPU + highest end performance relative to the best IGP.
3) Lower graphics performance requirements.
4) Wait a year or two before buying, and accept that you still don't have the then current best IGP but will have the IGP performance of when you started on this journey in early 2013.

Zap, I'm afraid you are right. The "best current" IGPU will never be offered except on the top processors. I can bellyache all I want, but it won't change. That's just my lot in life.

I won't get too glum, though. I guess it gives me the opportunity to really customize my CPU/GPU setup even more. I just have to accept a discrete GPU. I'm thinking at this point, I should probably wait for Haswell to launch. If the TDP of Haswell drops 15 or 20% below Ivy Bridge levels, then that would give me more head-room for GPU TDP on an mITX build. What say ye about this prediction?


You said you had a hand brake and some rivet tools. I want to build my own case to make it the exact dimensions. I'm either going to use L-brackets to fasten the panels together, or I will bend tabs on the edges and rivet them together.

What would be a good "sheet metal" material to use for the sides? I don't want something cheap like flashing, but not something so expensive that it costs more than buying a case alone. Maybe something $5-10/sq. ft. What are my options?

 

[Zap]

I just have to accept a discrete GPU. I'm thinking at this point, I should probably wait for Haswell to launch. If the TDP of Haswell drops 15 or 20% below Ivy Bridge levels, then that would give me more head-room for GPU TDP on an mITX build. What say ye about this prediction?

Sounds good to me. But seriously, if you up your budget to around $120-130 you can get either an i3 with HD 4000 (or whatever Haswell has) or an AMD A10. Note that people have had issues running the A10 in an Antec ISK 110, meaning it is pretty power hungry.

Otherwise, if you have the power budget then a discrete card would be awesome for gaming. For instance in the performance graphs I posted earlier, a Radeon 7750 is over twice as fast as the fastest A10. Radeon 7750 does not require additional power as it stays within a 75W power envelope. In fact, I have used a 6670 as well as 7750 in my Antec ISK 300-150 with the stock 150W PSU and a quad core Core i5-2500K (stock clocks all around) and it never had power issues.

The real reason for a Radeon 7750 (why I keep mentioning it) is that it is the best card you can currently buy that is single slot low profile and doesn't require additional power. This keeps the size down.

Oh yeah, besides using external bricks, you can use Flex ATX PSUs. Seasonic SS-250SU for instance is a powerhouse in a tiny enclosure. You can get it for as low as $40+shipping, and it uses normal power cords. It is 5.9” x 3.2” x 1.6” in dimension, making it similar in size to power bricks of similar wattage.

BTW I finished fiddling with my new notebook (made sure it worked, then cloned HDD to a spare SSD, then swapped drives) and installed League of Legends on it. Low 1366x768 resolution, everything on "medium," locks in at 60FPS and looks fine to me. It defaulted to "high" settings which knocked FPS down to around 30, which was okay but didn't feel as smooth.

What would be a good "sheet metal" material to use for the sides? I don't want something cheap like flashing, but not something so expensive that it costs more than buying a case alone. Maybe something $5-10/sq. ft. What are my options?

Aluminum. You can find it for under $5/sq.ft. You can buy online, or pick up some at your local Menards/Lowes/Home Depot. It is probably the only metal that you would find easy to manipulate with mostly hand tools and maybe a bending brake and drill. Other metals are too hard to deal with easily, unless you were a pro at this, and then you wouldn't be asking.

 

[2timer]

Update: I think I'm going to go CPU/discrete GPU now. I suppose I don't *have* to make the GPU external if using a 90 degree riser. That would still be minimal enough, I suppose. I wish AMD offered a mini 7750 like the 650 TI. http://www.newegg.com/Product/Product.aspx?Item=N82E16814130839 The TI is the perfect size for an mITX build, it's just too expensive! I guess budget mITX graphic cards are still "too far" in the future.

I think I'm going to go 1155 for this build. I'm 99% sure Intel won't offer the GT3 IGP on a budget processor, so no use in me waiting on something that will never come. The drawback is overall TDP with 1155 will be higher, but like you said, I can add a flex ATX PSU if necessary. Hopefully a Pico PSU will be enough, though, but we'll see.

In terms of materials, I looked at wood, acrylic, aluminum, and ABS plastic. I think I will either go with black ABS plastic or a simple brushed aluminum painted in black. That would be simple and elegant. But the ABS plastic would be cheap and easy. Hell I'll probably do the ABS plastic. This would be my first run so if I screw it up, it won't be as bad to fix!

How to brush aluminum
How to machine plastics