How I Built the Ultimate Portable Mac Mini Setup with 3D Printing

In the ever-evolving world of technology, the quest for portability and power continues to push the boundaries of innovation. Among the latest devices that inspire creativity and experimentation is Apple’s Mac Mini—a tiny yet incredibly powerful desktop computer that has captured the attention of tech enthusiasts and creators alike.

For years, the Mac Mini has been a quiet contender in Apple’s lineup, offering exceptional computing power in a compact form factor. However, its desktop nature raises an intriguing question: can you turn the Mac Mini into a portable powerhouse without compromising its features or performance? That’s exactly the challenge I set out to tackle, and the journey led me to build what I believe is the ultimate portable Mac Mini setup.

Let me take you through the entire process—from concept to design, prototyping, testing, and finally, creating a setup that blends functionality, aesthetics, and usability in a uniquely satisfying way.

The Spark of an Idea: Why Make a Portable Mac Mini?

When I first got my hands on a new Mac Mini, I wasn’t exactly sure what I wanted to do with it. Fans of my previous projects had been requesting a new Mac Mini build for a while, and I wanted to create something different from the usual desk setup. It wasn’t until I started exploring its compact size and performance capabilities that the idea hit me: what if I could turn the Mac Mini into a truly portable workstation?

People already carry around laptops with external monitors, but I was intrigued by the challenge of integrating the Mac Mini with peripherals like a keyboard and monitor into a single, transportable unit. It had to be practical, ergonomic, and stylish—something that would blend seamlessly with Apple’s minimalist aesthetic while solving real-world usability challenges.

Defining the Design Goals

Every great project starts with a clear set of goals. For my portable Mac Mini setup, I prioritized the following:

1. Built-in Keyboard – I wanted to avoid carrying a separate keyboard, so the design had to incorporate Apple’s Magic Keyboard directly into the setup.

2. Integrated Monitor – A portable monitor that could attach securely to the Mac Mini, ideally with a touchscreen for added functionality.

3. Accessible Ports – All ports on the Mac Mini needed to remain easily accessible without awkward reach-arounds or disassembly.

4. Ergonomic and Balanced – The setup couldn’t be too top-heavy or awkward to use on a desk or lap.

5. Sleek Aesthetic – It needed to feel like a natural extension of Apple’s design language, not just a rough DIY hack.

With these requirements in mind, I began assembling the core components and brainstorming ways to bring everything together.

Choosing the Components

For the keyboard, I selected the Apple Magic Keyboard, known for its slim profile, lightweight build, and comfortable typing experience. I managed to source an older model without the fingerprint sensor, which was more affordable and widely available on the secondhand market.

Next, I searched for a portable monitor that could complement the keyboard’s dimensions. After some digging, I found a monitor that was not only similar in width but also had VESA mounting points—a critical feature for securely attaching it to a custom enclosure. Even better, the monitor was touchscreen-enabled, providing a layer of interaction beyond standard displays.

However, I immediately ran into a challenge: the monitor was heavier than expected. While this added to its premium feel, it also posed potential balance and stability issues when combined with the much lighter keyboard. I knew I’d have to address this imbalance in the design.

The Design Iteration Process

My initial sketches explored several configurations. Should the keyboard attach directly under the monitor? Should the Mac Mini sit behind, beside, or below the screen? Each layout had pros and cons.

One early idea involved placing the Mac Mini behind the monitor and letting the keyboard fold up to close over it. But this blocked access to the Mac Mini’s ports and power button, making it inconvenient for daily use. Turning the Mac Mini on its side improved port access, but created an awkward protrusion that disrupted the design’s clean lines.

I experimented with positioning the Mac Mini under the monitor, using its weight to counterbalance the screen and prevent tipping. While this approach provided better stability, it added bulk and raised ergonomic concerns—placing the screen too high for comfortable viewing at a desk.

After several mockups, I realized the simplest solution was to anchor the Mac Mini beside the keyboard, using its mass to counterbalance the monitor while preserving port accessibility and keeping the screen at a comfortable height.

Prototyping with 3D Printing

To bring my design to life, I turned to 3D printing, which allowed for rapid prototyping and custom-fit parts. Given the size of the enclosure I envisioned, I needed a large-format 3D printer. Thankfully, I had access to the Bambu Lab H2D, an advanced 3D printer with a large build volume, dual-nozzle system, and features that made this ambitious project possible.

The H2D proved to be a game-changer. Its automatic ventilation, print progress lighting, and precision dual nozzles allowed me to experiment with support materials and complex overhangs that would’ve been nearly impossible on a basic printer. Removing supports was a breeze, and the resulting prints had an impressive surface finish right off the bed.

Refining the Details

Once the core structure was printed and assembled, I noticed a small but important issue: the plastic enclosure created an unpleasant noise when resting against the desk. To fix this, I used the H2D’s dual-nozzle capability to print TPU soft pads that I embedded into the base. This simple tweak drastically improved the tactile feel and sound dampening of the entire setup, while adding a professional polish to the design.

I also custom-painted the monitor’s enclosure to match the aesthetic of the Mac Mini and keyboard, using a subtle silver tone to evoke Apple’s signature finishes. However, I worried about paint durability—repeated opening and closing of the screen could scratch the finish over time. Thanks to the TPU pads, the screen now rested gently against the enclosure without damaging the paint.

Evaluating the Performance

With everything assembled, I spent a few days using the portable Mac Mini setup as my primary workstation. The touchscreen monitor performed admirably for basic navigation, scriptwriting, and light editing tasks. Its aspect ratio created a focused, typewriter-like feel that I found surprisingly enjoyable for writing.

However, I discovered the touchscreen’s limitations—without multi-touch support, it couldn’t replicate the gestures I was used to on an iPad or MacBook. It worked well for simple taps and drags, but wasn’t suitable for detailed drawing or multitouch controls.

Audio was another weak spot. While the monitor included built-in speakers, they were surprisingly worse than the already underwhelming speakers inside the Mac Mini. For any serious audio work, I still had to rely on external speakers or headphones.

Is It Truly Portable?

Some may argue that because the setup still requires a wall outlet for power, it’s not “fully portable” in the way a laptop is. And they’d be right—this setup isn’t designed for airplane tray tables or off-grid work. But for coffee shops, coworking spaces, or anywhere with reliable power access, it offers a compelling alternative to lugging a full desktop or compromising with a less powerful laptop.

While building this setup, I also started thinking about how I could make it completely battery-powered in a future iteration. Such a version would require additional components like power banks, voltage regulators, and possibly a thicker enclosure to house the batteries. If enough people are interested, I’d love to explore this challenge in a follow-up project.

Sharing the Design with the Community

I believe in the power of open-source sharing and collaborative creation. That’s why I created a version of the portable Mac Mini design that can be printed on smaller 3D printers like the Bambu Lab X1C or A1. By optimizing the design for modular printing and assembly, I’ve made it accessible to more makers who might not have a large-format printer.

For those interested in building their own, I’m making the 3D printing files available through my membership program. Members also get access to exclusive behind-the-scenes content, including detailed tutorials, lessons learned during the design process, and insights into the prototyping challenges I faced.

Reflections on the Project

This project reminded me why I love DIY builds: the joy of problem-solving, iterating, and arriving at a solution that feels both practical and personal. The portable Mac Mini setup might not be for everyone, but for someone who values portability, power, and modularity, it strikes a unique balance.

And I couldn’t have completed it without the Bambu Lab H2D, which proved to be a versatile and reliable tool. Beyond just 3D printing, its plotting and engraving capabilities open up new creative possibilities for future projects—something I plan to explore as space and time allow.

Final Thoughts

In a world dominated by pre-packaged consumer electronics, it’s refreshing to reclaim a sense of agency over our tools. Building a portable Mac Mini workstation isn’t just about saving space or showing off DIY skills—it’s about creating something that fits your workflow, your aesthetic, and your vision.

Whether you’re inspired to build your own, modify an existing setup, or simply appreciate the ingenuity behind such a project, I hope this journey sparks ideas for your next creative endeavor.

If you’re interested in building your own portable Mac Mini setup, accessing the 3D printing files, or diving deeper into the build process, consider joining my membership community for exclusive resources and tutorials. And stay tuned—because this is just the beginning of what’s possible when you blend powerful tools with a little imagination.