Introduction: 3D Printed Bose Soundlink Mini Clone

Hello everyone!

I’m going to show you to build clone of the most famous and the best sounding in the class Bose Soundlink mini. The last four months I been collecting information about this speaker, trying to find simple, cheap and good sounding hardware. Also, a lot of time took to design enclosure, printing samples. This project is open source, you can download enclosure and print it, all parts are widely available on Ebay or AliExpress.

Step 1: Components

You will need next components:

1. 3D printed enclosure

2. 2x 10W 40mm 4Ohm Bose Soundlink Mini drivers (Clone)

3. Bluetooth Audio Module Sanwu with Yamaha YDA138

4. 2x Passive radiators

5. Li-ion 2S protection board

6. Li-ion 8.4V 2A charger

7. 2x 18650 Li-Ion Battery

8. Adjustable step-up module with XL6009

9. Connector DC 5,5/2,1mm

10. 3A 250VAC rocker switch

11. JST-XH-2, 2pin connector with cable

12. JST-XH-3, 3pin connector with cable

13. Wire about 0,5m

14. 8x M3x50 F-F spacers

15. 22x M3x8 imbus screws

16. 10x M3 nuts

17. 2000uFx16 capacitor

I will add links later.

3D printed enclosure:

Designed in Fusion 360, suppose to take together all component, almost without gluing. Printing in PLA 0,2mm layer about 15 hours.

Clone of Bose Soundlink mini drivers:

10W 40mm 4Ohm driver with neodymium magnetic. It’s really good driver for this size and cost.

It’s wireless Bluetooth speaker, so we need a battery, a big one capacity :) I choose 18650 Li-ion because it’s small battery and have enough capacity for 5 hours of loud music :)

Bluetooth Audio Module Sanwu with Yamaha YDA138:

I took this one from several modules I’ve tested. It has 2x15W on 4Ohm drivers. You will need to solder JST connector on it. To prevent mistakes in the future, you should to fide directions of JST connectors (red wire must be “+”), like on the picture:

Passive radiators:

It’s also clone of Bose passive radiators and they have been designed to work with Bose Soundlink mini speaker drivers. They do their job very well.

Li-ion 2S protection board, 8.4V 2A charger and 18650 Li-Ion Battery:

You need to put together two batteries and protection board with printed brackets. Before we start wiring, it's important to check battery voltages, it should be the same.

Before you start solder batteries I would recommend sanding a little the contacts, where you will solder, put some flux and solder. Do it as quick as possible, do not overheat the battery! Connect batteries with protection board like on the scheme.

Adjustable step-up module with XL6009:

To power our Bluetooth module with amplifier we need to boost voltage form battery pack 7,4V to 13-14V. Connect module to the power source and adjust with the pot output voltage to 13-14V.

Step 2: Schematic

Step 3: Wiring and Mounting, Back Part

Now, when we have all prepared, we can start.

Take the back side of Speaker, put passive radiator to it place, put spacers and screw screws from back side, do not tight much, leave it loosed. Place DC 5,5/2,1mm connector and rocker switch, wire up with step-up module input like on schematic. Solder prepared (pay attention for “+” and ”-”) JST-XH-3 connector to the step-up module output. Attention! Solder minimum 2000uFx16V capacitor to the output of step-up module. Secure wires and step-up module with glue gun to the enclosure to prevent vibrating and making noises.

Step 4: Wiring and Mounting, Battery Pack and Amplifier

Take our prepared battery pack, screw to the bottom and solder to 5,5/2,1mm connector.

Take amplifier adapter, sand it a little bit in guides place, it should be tight in the back part guides. Take amplifier, screw to the adapter and put to the back part. Place 2 bottom spacers and is better to isolate right spacer by adding shrink tube to prevent battery short circuit.

Step 5: Wiring and Mounting, Drivers

Take drivers and solder wires with JST-XH-2 connectors, maybe you will need to make wires longer. Screw drivers to the face part of speaker like on picture. That’s it!

Connect amplifier with drivers and boost module, pay attention for left and right channels.

Step 6: Wiring and Mounting, Screw It!

Better if you try it now before screwing. Turn on the

speaker, take your phone and search for a Bluetooth device called "Xpecial Audio". Connect and try to play a song. Does it work? Great! We can continue!

Add passive radiator and screw back and face parts, switch on and try the perfect sound from your DIY speakers ;) .

PS: to prevent vibrations and run away your speaker, add rubber foot pads.

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