[quote name='Blaster man']Mine makes a disturbing and loud cracking sound at least once each time I use it. I have no idea what makes the sound but I assume it's a component heating up. Seems like a bad design. I have a slim.[/QUOTE]
I think that's the external casing (plastic) expanding from heating up as the system is in use. Mine makes the same noise, but after I turn the system off (plastic contracting from cooling). It's been doing it forever and very consistently, so I wouldn't worry too much about it.