The new power management IC runs very hot—almost as hot as the CPU. Most designers focus on CPU vents but forget the PMIC (located near the USB-C port). Ensure your model has vents directly above that chip.

Many early models were simply Pi 4 cases with "Pi 5" in the filename. They lack the 7mm x 5mm cutout needed for the PCIe FPC connector. If you plan to add an NVMe drive later, ensure your case has a removable side panel or a dedicated slot.

Unlike its predecessors, the Raspberry Pi 5 introduces several physical changes that affect mechanical design:

Here are some exciting projects and ideas to get you started:

Do not use PLA for a fully enclosed Pi 5 running 24/7. The CPU will soften the plastic over time, causing the board to sink into the standoffs and short out.