Laser Cut Clip Together Mono Amplifier Case

The cover of our Easter 2019 D&T Update features this nifty clip together acrylic case. This is a super easy project, showcasing design, materials, and a small amount of soldering. The design files for the project are available, so you can quickly cut one for yourself. Clip Case in Acrylic The website Thingiverse is used as it's where this simple clip together box design was first found. The design works well with acrylic and extremely well with manufactured woods like laser friendly MDF and Ply. Grab the files here.


Laser Cut Clip Together Mono Amplifier Case:

A step-by-step guide on how to assemble this project follows. The original project was cut from Acid Green Perspex, this tutorial uses Gold Metallic Perspex. It is photographed on Orange Perspex Sheet. We used one of our amplifier kits for the build, you can find a pre-built mono amplifier kit here.  


Prepare the file for laser cutting

The file provided is a dxf, this is Drawing Interchange Format, or Drawing Exchange Format. Which is a Computer Aided Design (CAD) data file format developed by a design company called Autodesk. With the specific reason to enable data interoperability between AutoCAD and other programs. It has become somewhat of a standard for CAD files used for laser cutting, and most laser cutter software packages will read it.

The dxf file is compatible with most laser cutter software packages


The file is colour coded so it is possible to cut the internal parts first, so they won't fall into your laser cutter. The settings shown are for a 40W laser cutter. 


Cut out the design

Each laser cutter will vary, but we trust you will know how to operate your laser cutter. The next stage is to cut the design.

Cutting is easier with lasers Our 40W laser cutting out the clip together box design


There is a stage here where the protective coating is removed. The laser cutter does the work for you. It would be possible to cut using a fret saw, but that would require a lot more work.    


Prepare the Mono Amplifier Kit

This could be done while the laser cutter is cutting the box. For speed, the pre-built Mono Amplifier kit was used. In this kit, the majority of the soldering is done, and only the speaker, battery box, and headphone jack need soldering onto the board. This was made easier by adding a light coating of solder to the ends of the wires once they were stripped ready to solder in, otherwise threading the stripped wire through the strain relief holes was a little tricky.   The assembled Mono Amplifier Kit looks like this.

It's prebuilt, so you only have to do a minimal amount of soldering The Kitronik Pre-build Mono Amplifier Kit


Assemble the case

Flat pack amplifier case A view of the case laid out flat.


The first step in assembly is to thread through the battery cage and headphone jack through the L-shaped part of the case. This is the middle part of the case, it holds the back of the speaker and also the PCB for the mono amp.

Put those wires through Threading the wires through the L shaped part


With the wires threaded through screws, the nuts can then be added to the corners of the PCB to prepare it for mounting on the L shaped part.

Nuts and screws y'all Using 10mm screws in each corner the PCB can be attached to the L shaped part


With the screws in the corner of the PCB it can then be attached to the L shaped part with four more M3 nuts.

Screws on Pay close attention to how this is attached.


The next parts of assembly involve laying parts out on the desk and also working out for yourself how it goes together. The images that follow will show you, but it will be easiest if you have worked it out for yourself first.This just fits as a friction fit Slot one side into the front piece of the box


Next, the L shaped part is added to the assembly. Also, ensure the speaker is lined up with the holes on the front of the box and slotted into the circular part of the L shaped part.

Just resting together The speaker placed onto the grill area and into the hole on the L shaped part


Slot and hold the second side into place.Hold together if you can Add the second side and hope it all holds together for the next part


 Now add the door, which will also act as a battery compartment. Hold it together if you can Adding the hinged part for the battery cage can be a little fiddly, the next step pulls everything together.


Next, add one of the end parts, these are both the same, so either will do. Then, clip the larger hole over the solid lug (topmost in the image below).Rest it on top before clipping it together Putting an end part over the assembly before clicking into place.  


With a soft click, the end part will hold the assembly together, hopefully, all of the side parts have also kept themselves together. Clip it, clip it good. End part clipped into place.


Now that the hinged door can be used, flip it up and slide the headphone jack through one of the holes on the side. This is so you can easily connect the Mono Amp to your phone. Pop it through Slot the headphone jack through one of the side holes in the case


Clip on the remaining end piece, then place the battery box into the case. Clip it on. Clip on the last piece, using the same technique as the other end.


Insert two AA batteries and then close the rear of the case. The, stand it up, plug it in ,and admire your creation!Mono Amp The completed Clip Case Mono Amplifier Kit


Finally, we hope you have enjoyed this build tutorial and look forward to hearing your feedback.

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