Firstly
@foureight84 , nice bracket design! I've had to make a few brackets myself in the past and never thought to make them flat & then bend and glue. Brilliant!
Uhm OK ... I doubt the Power Consumption difference is that huge if the NIC shuts the other Port Down (IIRC you can also force it via mlxconfig).
Power Consumption Difference will be completely irrelevant if you do NOT have ASPM working. And these Mellanox ConnectX-4 NIC only seem to work with ASPM if the NIC is placed in a PCH-connected/DMI-connected/Chipset-connected Slot, NOT to a PCIe Slot that is directly connected to the CPU !
Yeah, this...I think? I think the single port and dual port cards have the same chip and nothing special is done to fuse anything off. The single port card just doesn't have the components for the second transceiver cage. And that shouldn't add too much..I think?
For folks without a printer or sheetmetal skills, the dual port brackets ought to fit the single port cards. You'll just have one extra large ventilation hole

. Single lots are relatively cheap on Ali Express. In the U.S 5 pack from this person seems like a good deal if you need a few:
Pardon Our Interruption... . Just be sure and check the spacing between the transceiver cages. Actual Mellanox, Lenovo (maybe others) have a larger spacing than the Dell ones.
Nope.
3d printing is for art and prototyping.
Notice that that "production" is not in that short list.
I think 3D printing has broken into the mainstream, and Production is on the list now, even for things that could be made through other means. In the last couple months I've bought gardening and pottery gear that contained 3D printed components. A friend that works for an international railway rolling stock manufacturer told me that they now use 3D printers in their repair/refit facilities to make on-demand repair parts, especially for older equipment. He tells me that its cheaper than maintaining stockage at multiple facilities and/or shipping from central logistics facilities and/or ordering up new production runs of vacuformed, injection molded, or even fiberglass parts. My neighbor the car enthusiast and his friends 3D print parts for their cars. Not just cosmetic stuff, but also gaskets, seals, airflow, heating/cooling, etc.. 3D printing is apparently a big deal with gearheads these days.
Ad-hoc printing a small number of these things is literally what the technology was invented for.
I think 3D printing is for lots of stuff...including this ^^