Introduction
If you love DIY electronics and want to build something that looks premium and sounds amazing, this 3D Printed 10W Bluetooth Speaker Box project is perfect for you. In this project, I designed and assembled a compact yet powerful Bluetooth speaker using a 3D printed enclosure, a PAM8403 stereo amplifier, and dual 5W speakers. The result is a portable speaker box that delivers clear vocals, balanced bass, and long battery backup, all packed inside a stylish 3D printed body.
The best part of this project is that it is simple, budget-friendly, and beginner-friendly, yet the final output feels professional and market-ready. I have explained every step in very simple words, exactly in the order I built it, so you can easily follow along and make your own version at home. This speaker box is ideal for home use, outdoor trips, workshops, travel, or even as a handmade gift.
Project Overview
This Bluetooth speaker box is designed to deliver 10W total output power using two 5W speakers driven by a PAM8403 stereo amplifier. The enclosure is fully 3D printed, which makes the design compact, lightweight, and customizable. A rechargeable lithium-ion battery system ensures long playback time, while the TP4056 module provides safe and easy charging.
Key highlights of this project:
- Compact and strong 3D printed enclosure
- Clear and loud sound output
- Rechargeable battery with long backup
- Easy charging using TP4056 module
- Portable design with top hanging handle
- Clean internal wiring and professional finish
Components Required
- 3D Printed Enclosure Body
- PAM8403 Stereo Amplifier Board
- Bluetooth Audio Receiver Module
- 5W Speakers × 2
- 3.7V Lithium-ion Battery × 2
- TP4056 Charging Module
- Double Channel Potentiometer (Volume Control)
- SPST On/Off Switch
- Connecting Wires
- Screws (0.5 inch)
- Hot Glue Stick
- Fevikwik
- Soldering Iron, wire and flux
Step 1: Preparing the 3D Printed Enclosure
I started this project by preparing the 3D printed enclosure. The enclosure design included a provision for a round power switch. The STL file for this enclosure was downloaded from Thingiverse, so modifying the original design was not possible.
Instead of changing the STL file, I used a simple and effective method.
What I did:
- The enclosure already had a round hole for a switch
- I didn't get same switch size in the market
- So I used rectangle type SPST switch
- I carefully heated a soldering iron
- Slowly reshaped the round hole into a rectangle
- Took proper care to avoid melting excess plastic
After a few minutes of careful work, the rectangle switch fitted perfectly into the same position. This method saved time and avoided the need to redesign or reprint the enclosure.
Step 2: Fixing the Speakers into the Speaker Enclosures
Next, I moved on to fixing the speakers.
Each speaker has its own dedicated enclosure inside the main body. These enclosures are designed to provide better sound direction and reduced vibration.
Installation process:
- Placed both 5W speakers inside their respective enclosures
- Used hot glue stick to fix them firmly
- The design also provides screw holes, so screws can be used for extra strength
For my build, hot glue was more than sufficient. However, if you want maximum durability, you can use screws in the given space.
Step 3: Attaching Speaker Enclosures to the Main Body
After fixing the speakers, I attached both speaker enclosures to the main enclosure body.
- Ensured correct left and right speaker alignment
- Pressed the enclosures firmly into place
- Checked for air gaps to avoid sound leakage
A proper fit ensures better bass response and cleaner sound output.
Step 4: Installing the Power Switch
Once the speaker enclosures were secured, I fixed the SPST power switch.
- Inserted the rectangle switch into the modified hole
- Used hot glue stick to secure it tightly
- Made sure the switch action was smooth and accessible
This switch controls the main power supply to the amplifier and Bluetooth module.
Step 5: Mounting the Double Channel Potentiometer
The next step was installing the double channel potentiometer, which acts as the volume control.
- Inserted the potentiometer into the provided gap
- Aligned it properly from the front panel
- Tightened it using the nut and washer
This potentiometer allows smooth and independent control of both left and right audio channels.
Step 6: Electrical Connections and Battery Setup
Now came the most important part of the project – wiring and connections.
Battery configuration:
- Used two 3.7V lithium-ion batteries
- Connected them in parallel
- This keeps voltage at 3.7V while increasing capacity for long backup
Connections made:
- Battery positive and negative connected to the amplifier power input
- Bluetooth module audio output connected to PAM8403 input
- Potentiometer connected between Bluetooth module and amplifier
- Power switch placed in series with battery positive line
All solder joints were kept clean and strong to ensure reliability.
Step 7: Installing the TP4056 Charging Module
To make the speaker rechargeable, I used a TP4056 charging module.
- Fixed the TP4056 module inside its dedicated charging enclosure
- Connected battery terminals to B+ and B-
- Power output taken from OUT+ and OUT-
- Charging port aligned perfectly with the back panel cutout
This module provides safe charging, over-charge protection, and battery safety, which is very important for lithium-ion batteries.
Step 8: Final Wiring Check and Testing
Before closing the enclosure, I carefully checked all connections.
- Switched ON the speaker
- Connected a mobile phone via Bluetooth
- Played music at low volume first
- Gradually increased volume
The sound output was clear, loud, and distortion-free. Vocals were sharp, and the stereo effect was clearly noticeable.
Step 9: Closing the Back Panel
Once testing was successful, I closed the enclosure.
- Placed the back panel carefully
- Used 0.5 inch screws to secure it
- Ensured tight fitting without damaging the plastic
At this stage, the speaker box already looked clean and professional.
Step 10: Attaching the Top Hanging Handle
To improve portability, I attached a top hanging handle.
- Applied Fevikwik on the handle joints
- Fixed it firmly on the top section
- Allowed it to dry properly
This handle makes the speaker easy to carry during travel or outdoor use.
Final Result and Performance
After completing all steps, the 3D Printed 10W Bluetooth Speaker Box was fully ready.
- Stylish and compact design
- Strong and clear sound
- Long battery backup
- Easy charging
- Portable and durable
Now you can play music and enjoy crystal-clear vocals and powerful sound anytime.
Where You Can Use This Speaker Box
This Bluetooth speaker box is perfect for:
- Home music system
- Outdoor trips
- Small parties
- Workshop or garage
- Travel and camping
- DIY electronics showcase
Conclusion
This 3D Printed 10W Best Bluetooth Speaker Box project is a perfect combination of electronics, creativity, and practical design. By following simple steps and using easily available components, you can build a professional-looking Bluetooth speaker at home. The 3D printed enclosure adds a premium touch, while the powerful sound output makes it truly satisfying to use.
If you enjoy DIY electronics projects, this speaker box is definitely worth building. Turn it ON, play your favorite music, and enjoy the sound! 🎶
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