Make a Speaker Smart Paper Case by Hand

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

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.

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.

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.

Assembling

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

Try Again

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

Have fun!