I wanted to make a speaker with acrylic sides, so you can see through the window inside the case.

Step 1: Designing

I first need to know what I want to put inside the case, for me it is:

-A simple amplifier

I wanted to go with a similar design as the speaker itself. Only thing i wanted was something with plexiglass so you can see what's inside it. But to fit everything inside the box, the box needs to be a little bit different. I choose some dimensions, what i thought would be large enough to fit all the components.

I made some sketchs of what I want to make.

I wanted the plexiglass on to front top en bottom in 1 piece. The back and the side must be wood. I made the designs in Inkscape to lasercut it later on. I also wanted to 3D print something. Because I had the change to do it. I made a 3D model of some offset pieces to put de pcb on, so the soldering points doesn't touch the bottom of the case

Step 2: Add Electronics

I made a circuit to create a simple amplifier, i used a lm368. it isn't a very loud amplifier, but it is enough for me. The components you need for this are:

-3.5mm audio jack female

-Power Supply (I used a 9V battery because of the small LED's)

-LM368

-1K resistor

-27K Resistor

-10 Ohm resistor

-22uF capacitor

-470uF capacitor

68nF capacitor

Step 3: Preparing Lasercutting & 3D Printing

to create the case of the speaker I used a lasercutter, so the dimensoons were excatly what I wanted them to be. First I made some models in Adobe Illustrator. To cut something, the lines must be red and 0.01mm thick. All of the colors will be engraved. I simply took all the measurements I did before.

Step 4: Lasercutting & 3D Printing

Lasercutting was actually really simple. When you open the project you made, you only have to set the dimensions and let it cut the project you made.

The gap where the aux-jack would have come was too small, so I made it bigger with a drill. that's the only part that's a little bit ugly. But I don't think it is a big problem.

When the acrylic was cut and I made the gap bigger. I wanted to curve the acrylic. I did this with a machine where 2 cables will heat the acrylic plate on the place where I want to bent it. Then when it's hot enough I put it against a table where I can change the angle of. So it becomes the angle I want it to be.

I 3D-printed 4 offset pieces to put the PCB on.

Step 5: Putting It All Together

When everything was printed and cut I decided to Put the speaker in the acrylic plate at first. and then the amplifier. When it all worked I soldered the on/off button (placed on the wooden backplate) to the amplifier itself. Then I glued the 2 side pieces to the acrylic plate. and then I glued the wooden pieces together.

So the project is done!