Previously, I had a brief introduction of using LibreCAD and Python to design a CAD file for a paper case. When we get a CAD file, we need a laser cutter to cut a paper case. However, not everyone has access to a laser cutter, so it would be cool if we can make a paper case by hand with our daily tool.

I also designed a new hardware. It has 4 microphones, 4 LEDs and a touch key. All of its components are mounted at one side of the PCB, which makes it easy to work with a paper case. The touch key can be used to enter Wi-Fi setup mode.

Supplies

scissors
knife
ruler
pencil
screwdriver
400g kraft paper
double-sided tape

Step 1: Draw the Outlines of the Paper Case

The paper is very simple. It's just a box with a lot of holes for a speaker, 4 microphones, 4 LEDs, 1 screw and 2 rivets. We can get the dimensions from the CAD file, and then use the pencil and ruler to draw the outlines.

Step 2: Cut the Outer Frame

Use the scissors to cut the frame following the outlines. To cut the speaker hole, we can use a similar size bottle cap to help.

Step 3: Drill the Small Holes for Microphones and LEDs

It's the most difficult part to do, as we have 4 microphones, 4 LEDs, 1 screw and 2 rivets. we can drill a hole with a screwdriver. Part of paper will be extruded. Use a knife to cut the extruded paper.