Case Study: Custom 1U Rackmount Monitor Workstation & Space-Saving LCD Console Drawer

Crystal Image Technologies was approached by two separate clients with unique, space-sensitive applications requiring custom 1U rackmount solutions. Both projects demanded innovation in compact environments while maintaining ease of access and hardware reliability.

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Client Overview

Project 1: 1U Thin Client Workstation in Rugged Mobile Application

Challenge

The client needed a complete 1U workstation, including a monitor, keyboard, mouse, and thin client computer, all integrated within a 1U rackmount drawer. The system had to fit within a 30" deep 6U rugged aluminium transit case. A key requirement was a removable hard drive to allow for easy replacement without bench testing.

Requirements

Removable 2.5" SSD Drive (Mobile Rack Bay)
Integrated CPU, RAM, and Thin Client with at least 1 GbE port
Mounting depth constraint: Max 30"
Fast delivery & 3-year warranty
Environmental Operating Range:
- Storage: -20°C to 50°C, 1–100% humidity with condensation
- Operation: 5°C to 30°C, 20–80% humidity, no condensation

Proposed Solutions

Thin Client Specs:

Intel Bay Trail Quad-Core CPU (up to 1.83GHz)
ThinX OS with 16GB Flash Storage
2GB RAM, 6 x USB 2.0, 1 x DVI (1920x1200), RJ-45 Ethernet
Power: 3W (nominal), max 6W, standby <1W
MTBF: Industry-standard with 3-year warranty

Integration Highlights:

1U rackmount console with custom I/O ports
Embedded removable 2.5" SSD mobile rack
Linux CentOS OS preinstalled
Upgraded internal power supply
Compact, mobile-ready design suitable for rugged deployment

Outcome

The result was a fully integrated 1U computer workstation optimised for mobile use. All hardware was housed in a single compact unit, successfully installed in the customer's rugged 6U case — eliminating the need for external components or additional rack space.

Client Overview

Project 2: Space-Saving Rackmount Monitor with Vertical Storage Feature

Challenge

The client needed to integrate a 1U rackmount monitor into a communication rack already crowded with vertical cabling and switches. The monitor was accessed infrequently, but traditional horizontal drawer designs obstructed the dense vertical cable paths.

Requirements

1U monitor with keyboard access
Minimal obstruction to vertical cable runs
Easy monitor deployment
Custom bracket design to fit existing 19” EIA rack

Proposed Solutions

Designed a 1U LCD monitor drawer with a left-hinged pivot to allow vertical stowage when not in use
Custom brackets designed using .DWG files from the client’s rack manufacturer
Secure anchoring to front LH rail, enabling a 10-second deployment
Cable management arm included for tidy storage of VGA, USB, and power cables
Easy access steps:
- Pivot into horizontal position
- Pull out drawer
- Flip up screen and use as normal
- Return to vertical position post-use

Outcome

The vertical-pivot design allowed the monitor to remain out of the way until needed, maintaining full access to rear cabling. The custom-engineered brackets and clever pivoting mechanism enabled quick deployment while maximising rack space efficiency.