Walls are made out of wood. All other parts are 3D printed or bought/used electronic parts. Front Panel can be swapped with different speakers for better sound quality. The speaker is portable thanks to my battery design and an included handle, but it can also be used stationary without a battery. It has Bluetooth but also an AUX input as well as output. Additional adapters for e.g. USB, Toslink, RCA can be stored in the compartment at the bottom or the top.
Features and Design Considerations:
Easily replaceable battery which uses standard 18650 Li-Ion cells
Easily replaceable speakers for e.g. extra Subwoofer, or tweeters, or passive Subwoofer. Customizable to your personal sound preference. The front should have enough space for 3 Speakers with a diameter of 93 mm and a depth of 55 mm (35 mm for the bottom one). If possible make sure to mount them in an irregular pattern for better sound quality.
Easily connect via different methods
Aux in, Aux out, Bluetooth (FYI each Aux port can either be used as import or output since it's an analog signal. I kept them separate to have more connection options)
USB-A, USB-C, Toslink, RCA, HDMI, etc. via Adapter which can be stored with the speaker
Easily Charge
Speaker without removing battery via USB-C PD! (12V)
Phone while using the speaker (5V slowly!)
Easy transport
Dimension are about the size of a 2L water bottle and should fit in any travel backpack.
Carrying handle which can be removed or made flat for better storage. Optionally can be added to the top as well
Speaker grills for protection in bag.
Battery life of at least 5 or more hours with incl. battery life indicator on the back
Use a a smart Speaker while phone is connected via Bluetooth
Removable Bluetooth Receiver which can be used as a Bluetooth beacon for non Bluetooth enable devices. Additionally if you don't one the have to turn it on and off with the speaker each time use one without a battery which turns on with power.
Anti vibration feet
Daisy chaining of multiple speakers possible.
Parts:
Wood (I used 8 mm Thickness but you can change this to your liking. I wouldn't however take a thinner wood):
1x Front-Panel (Cut holes according the your speakers, I used on one Midrange Driver, one Tweeter and one passive Sub)
2x Side-Panel (Left and right are identical)
1x Top-Panel
1x Bottom-Panel
1x Back-Panel
1x Battery-Back-Panel
1x Battery-Ports-Panel
3D Printed: (PETG/PLA etc.)
1x Input Ports Cover
1x Output Ports Cover
1x Charging Ports Cover
1x Battery Spacer Left (They are just mirrored)
1x Battery Spacer Right (They are just mirrored)
1x Handle-Strap TPU!
2x Handle Screw
2x Handle Screw Socket
1x Bottom Box
1x Bottom Box Baseplate
1x Top Box (Change these last two Top Box parts of you are using a different Bluetooth Receiver and or if you need holes for a Top mounted handle)
Wire up everything according to the following diagram (Power Red, Audio Blue). Assembly everything outside first and test functionality.
Test if Power button correctly turns off battery display after approx. 30 seconds
Test if Power Failure Automatic Switching Module correctly switches to USB-C input source once connected and reconnects the battery afterwards.
Test if audio works on all input and outputs and doesnt hiss.
Test if smartphone can be charged while speaker is powered on.
Cut wood parts and assemble like the following picture. I attached everything together using nails and wood glue. Except for the Front-Panel which I kept open at this point.
I now added holes
for all the input and output ports
for the battery ports
for the Bluetooth Receiver at the top
for the handle (12 mm)
Afterwards I could add all the electronic parts. I attached them with hot Glue and 3M Tape. Also don't forget to glue down "Handle Screw Socket"
Afterwards I attached the Front-Panel using small screw plus 3M Tape.
Now the remaining 3D printed parts like Ports Covers and Bottom Box as well as Top Box could be glued down.
Now just add the TPU Handle and some rubber pads on Boom Done 👍
Tip! When choosing Amps and speaker match power draw and impedance correctly!
Tip! Please don't try to 3D Print the whole speaker. Hollow or Thin 3D printed walls sound poorly and wood is so much cheaper. The kind of wood mostly does not matter. Thicker wood will sound better but weight more.
Putting the speaker grill over the whole front would remove the need make it fit into the speaker holes. A stiffer grill could also be used to improve protection
Designing 3D printed insert for Ports in which they perfectly fit in. This would make installing all the port easier and remove the use of a Dremel.
Changing the power button with one that doesn't stick out of the speaker body so it doesnt get pressed accidently when laying on the back or in a bag.
Installing more powerful speakers and AMP
Maybe slightly angle the base to make speaker face user more directly
All Files are free to use and available as STEP files.
Razzer09
