Make a Speaker Smart Paper Case by Hand

About: An engineer who loves making things

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

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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.

Step 4: Assembling

Use rivets to mount the circuit boards on the paper, and then fix the box with double-sided tape.

Step 5: Try Again

Like other things, practice makes us better. So I did it again. You can see the difference.

Have fun!

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