Create a Small Laser Cut Amplifier (enclosure)




Need a mini amplifier?  Have an old pair of wired speakers?  This instructable is for you!
I tend to prefer wired speakers over bluetooth but have minimal space for my old large amplifier.  I wanted something small and cute to use with my TV and set of desktop speakers.  I also wanted a system that had a stereo-mini port and could be plugged directly into my iPhone, android or iPad to play music.  I ended up ordering a small amplifier on and creating the case using 1/8" plywood on the laser cutter.  Made at the TechshopSF.

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Step 1: The Amplifier.

I chose the LP-2020A+ Lepai Tripath Class-T Hi-Fi Audio Mini Amplifier with Power Supply (Black), available for about $20-25 on and other sites.

Here are the specifications for you audiophiles:

Size: 110mm (D) X 140mm (W) X 40mm (H)
P.M.P.O : 2 x 180W
R.M.S : 2 x 20W
Input power : DC10~14.4V≧3A
Input sensitivity : 200mv
Frequency response : 20Hz - 20kHz
Speaker impedance : 4 - 8ohm
Minimum THD : <0.4%
Signal noise / ratio : >80db
RCA ans stereo mini input 

Step 2: The Enclosure.

I designed this enclosure using a "living hinge" because I think it draws people's attention and looks good.  Laser files attached (.ai and .pdf).  You should use 1/8" plywood that is at least 13" x 14".

You will notice that the amp enclosure has a little shelf on the inside which is what holds the amplifier in place.  The enclosure is assembled around the amplifier which is simply sandwiched in there.

I used a few dabs of glue at the finger joints and along the inside edge of the living hinge to hold the enclosure together.  For something this small, I usually just use some scotch tape to hold everything together while the glue is drying (at least 1 hour). I suppose you could use clamps but it seems like overkill.  My favorite wood glue is titebond II.

Step 3: Finish.

Finally, I gave the wood a light sanding and oiled with Watco oil.  Done! 

Thanks to the TechshopSF and also to user fasaxc for design inspiration.
Here is a link to his awesome Arduino radio enclosure.

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    12 Discussions


    6 years ago on Introduction

    Looks good!
    I have one of those lepai amps, they're a good deal for what they cost, though the audio quality can be sub par.

    2 replies

    Reply 6 years ago on Introduction

    If you need really really good quality you will have to pay more. We use it for our living room sound system and love it.


    6 years ago on Introduction

    Are the cut out notches 1/8 deep by 14 wide? if so what size is the diagram so I can make the ESP file reflect this. Looks like the file has been compress to fit on a single page.

    2 replies

    Reply 6 years ago on Introduction

    When I open the .eps file in illustrator, the artboard size is: 12.44" (width) by 13.36" (height).


    Reply 6 years ago on Introduction

    I'm not sure I understand your question but i will try to help. What program are you using to open the files? Adobe illustrator and Corel draw should open any of these without changes to the size.

    this is fantastic! okay, obviously i am biased as i am the beneficiary of this particular piece of amazing. i use this radio situation everyday and it is durable and wonderful and simple and gorgeous. i love bragging to all our guests that i know who made it.