This tutorial illustrates how to create cardboard speakers of your head.
-an iPad with Autodesk 123D Catch software to scan the image into CAD (free download)
*you may use a digital camera & Autodesk 123D Catch for online instead
-Autodesk MeshMixer software to massage & patch up the CAD surfaces (free download)
-optional Rhino CAD software for additional patching & refinements (free evaluation download)
-Autodesk 123D Make software to slice the CAD into sheets for laser cutting (free download)
-an Epilog laser cutter
-corrugated cardboard (36 sheets of 3/16" thick 36"x24")
-Sobo craft glue (available at craft & art stores)
-OrigAudio speakers ($16.00)
-portable power drill with 1/4" bit
-1/4" wood dowel or chop stick
-wire or straightened coat hanger
-a buddy to assist you with your 123D Catch
Step 1: 123D Catch Your Head
Step 2: Process the Catch
The first catch I did successfully captured my front, but as you can see in the second image my back is missing a large surface.
I did a second catch in hope of better success. The third & forth images are the results of this second attempt. For some unknown reason the catch was processed upside down, but that doesn't affect anything. The second catch captured my back much better, but kind of warped my face.
Step 3: Digital Surgery in MeshMixer
Step 4: Patch Holes in Rhino
Lesson learned: If your model has a cylindrical hole with critical dimensions (such as the hole for the speaker) & stacking layers parallel to the cylinder in 123D Make (like this tutorial), the hole will be too small. See Image 5 (pink line represents resulting hole for speaker). I found this out while I was assembling the layers & ended up having to cut out space for the speaker with an X-Acto. I tried exporting the sliced model from 123D Make into Rhino & then cut the speaker hole, but the geometry became a bit convoluted when imported again in 123D Make. Thus no real solution as of now.
Step 5: Slice Geometry in 123D Make
This particular size of model requires 18 sheets of cardboard resulting in 93 parts.
Step 6: Laser Cuttin'
Step 7: Disassemble the Speakers
Step 8: Glue the Layers
I started using Elmers glue, but it was taking awhile to set & I had difficulty adhering layers that were slightly bowed. I switched to the Sobo craft glue which worked much better.
Step 9: Route the Audio Wire
Step 10: Cut Out a Larger Space for the Speaker
Step 11: Solder Wires to Speakers
Now repeat for the other speaker!
Using a soldering iron, solder the wires back to the speakers. Test that speakers are in working order by plugging the jack into a iPod or computer.
Step 12: Admire at How Great You Look & Sound As a Speaker
Don't mind the strange looks from your classmates or coworkers, they're just jealous.