I wanted to make use of these little speakers I had lying around. The problem was, designing a box this small using wood would have been a pain.

Since I had a 3D printer, I decided to design and print my very own speaker box, custom for my purpose :)

I hope this Instructable will provide enough details on how to build one yourself! :)

Step 1: Designing the Speaker Box

This was my first project that I've designed myself using Fusion 360.

Here is the link to the model: https://www.thingiverse.com/thing:2795035

I measured the speakers and estimated tried to make the box as small as possible, taking all the electronics that will be inside into consideration.

NB: Please make sure you use the vernier caliper correctly when measuring. I made a mistake and was 3mm off on everything on my first attempt - good thing it wasn't that long to reprint.

Step 2: Tools and Components

Tools:

Soldering iron
Solder
Light gauge wire
Helping hands
Hot glue gun
Vernier caliper

Components:

PAM8403 2x3W amp
1850 Lithium-ion battery
TP4056 charge and discharge protection board
3.5mm jack
PCB Switch
Micro USB breakout board
2x3W speakers
Bluetooth module (optional) - with this, you can turn the speaker into a Bluetooth speaker

Step 3: 3D Printing the Box

I printed this using the following settings on my Anet A8:

Layer Height: 0.32mm - since this print didn't have a lot of detail, I used a higher layer height to allow for shorter print time ~5 hours
Filament: CCTree PLA 1.75mm
Infill: 50%
Print Temperature: 190/60
Print Speed: 60mm/s
Travel Speed: 120mm/s

Step 4: Fixing Mistakes and Reprinting

As I mentioned earlier, I originally measured incorrectly and thus my print came out 3mm smaller than intended.

Thus, I had issues trying to fit the speaker into the speaker hole.

You'll see in one of the photos above, I tried to use a rotary tool to make the hole larger, but failed miserably!

I then reprinted and stopped the print just after a few layers to test if the holes were correct.

I also realized I forgot to extrude the holes for the switch, jack and micro USB slot.

Link to model: https://www.thingiverse.com/thing:2795035

Step 5: Connect Components and Test

Before soldering, make sure you connect the wires via wire connectors and test everything is working

Step 6: Solder Components Together

Solder all the components together according to the provided schematic.

Step 7: Hot Glue Components Into Box

I used hot glue to stick all the components and they are fairly secure inside the box.

Step 8: Done!

I closed the box using the lid which snapped in perfectly - I didn't have to glue it shut.

The speaker isn't extremely loud, but can produce a fair amount of volume.

It was a fun project and incredible to see how you can go from idea, design and then producing a product in your hand. All made possible with 3D printing!