Originally posted by: kleptophobiac
I'm saying that once you have holes for airflow in the front (with no fan there) it shouldn't make a difference how restrictive they are. No fan is sitting right there, and the cracks and crevices should make up for the "slack".
I happen to have an Antec SX835II, the manliest case ever made.
Not only "should" it matter, it does matter both in theory and in practice, largely for two reasons:
1) Routing of airflow - air should travel length of case, minimizing air drawn in near the power supply or case exhaust fans except in special cases where extra spot-cooling is needed (possibly a Prescott P4 or o'c video card), though such a deviation requires more careful planning of front intake as a side-fan may very significantly reduce a passive front intake for HDD or southbridge cooling. That means at opposite corner from case and power exhaust, ie - front bottom of any typical case.
2) Fans are not constant-flow devices, their flow depends on amount of backpressure. The more "restrictive" the holes, the greater the backpressure and the lower the flow rate at any/every RPM and/or voltage. Intake fans can have their purpose, but whether there is an intake fan has no bearing on the impact of intake... an intake fan really only reduces backpressure for the exhaust fan and creates turbulence in it's immediate vicinity.
There are two main reasons why cases are not MUCH more open than they already are.
1) EMI - Cases themselves don't have to pass any EMI standards but systems built into them do, though you're not likely to get caught unless a big OEM.
2) Noise - It is more expensive to create a baffling or other noise-reduction system that keeps noise down AND allows good flow. Case manufacturers are primarily concered with profit and sales, not whether the case based flow vs noise possible.
There is of course another reason for cheap cases, that the metal is thin enoough such that the metal can't have holes TOO big else it will effect structural integrity too much. As it is some of the cheap cases already sway sideways after a system is built inside, if not picked up/moved very carefully.
On the other hand, you could just settle for a louder system... the smaller the intake area the faster the (same) fan will have to spin to exhaust at same rate. Even so, that these cases have the rear 120mm fan, does help. Sound escaping the rear of the case is reduced by the time you hear it, especially if under a desk.