You don't need a second case for the expander, but obviously you might if your primary case doesn't have space for all your drives.What I haven't figure out is whether I need a second case.
Can I just the SAS expander or do I need another card to use it?
A SAS expander as analogous to a SATA port multiplier. It takes a single SAS port and expands it to more ports. So it needs a compatible SAS port to plug it into, just like you can't use a SATA port multiplier without first having a SATA port. Unless you happen to have a motherboard with compatible SAS ports, then yes, you will need a SAS HBA to provide a SAS port to be expanded into more ports. See the first post of this thread for some examples of known compatible SAS RAID/HBA cards, as well as some SAS port equipped motherboards.