3D-printable speaker enclosures for building a custom voice assistant using ReSpeaker boards, a quality full-range driver, and external amplification. Designed as an Echo Studio replacement with Home Assistant integration.

This project provides parametric OpenSCAD designs for building a high-quality voice assistant speaker. Four enclosure variants are included to match different ReSpeaker boards and aesthetic preferences.

Features:

• High-quality audio from a proper full-range driver (not tiny onboard speakers)
• External amplification for room-filling sound
• 360° or directional sound options
• Fully parametric designs — customize dimensions easily
• Designed for FDM 3D printing

ReSpeaker Lite (~$25) — Budget-friendly, 2-mic linear array, good for smaller rooms

• Cube: Best for desk use, directional listening
• Cylinder: Room-filling sound, Echo-style aesthetic

ReSpeaker XVF3800 (~$55) — Premium 4-mic circular array with beamforming, 12 LED ring

• Cube: Conference use, noisy environments
• Cylinder ⭐: Best match — circular board + cylinder = true 360° experience

• Outer diameter: 104mm
• Cutout diameter: 86mm
• Mounting depth: 63mm
• Bolt circle: 95mm (M3 screws)
• Recommended sealed volume: 0.5–1.5L
• Frequency response: 65Hz–17kHz

                    ┌─────────────────────────────────────┐
                    │         12V 3A Power Supply         │
                    └──────────────┬──────────────────────┘
                                   │
                                   ▼
                         ┌─────────────────┐
                         │  Barrel Jack    │
                         │  (panel mount)  │
                         └────────┬────────┘
                                  │
                    ┌─────────────┴─────────────┐
                    │                           │
                    ▼                           ▼
           ┌───────────────┐          ┌─────────────────┐
           │  TPA3116D2    │          │   MP1584 Buck   │
           │  Amp Board    │          │   Converter     │
           │               │          │                 │
           │  VIN: 12V     │          │  IN: 12V        │
           │               │          │  OUT: 5.0V ⚠️   │
           └───────┬───────┘          └────────┬────────┘
                   │                           │
                   │                           ▼
                   │                  ┌─────────────────┐
                   │                  │   ReSpeaker     │
                   │◄── 3.5mm ───────│   Lite/XVF3800  │
                   │    Audio        │                 │
                   │                  │   5V pad        │
                   ▼                  └─────────────────┘
           ┌───────────────┐
           │   ND91-4      │
           │   Speaker     │
           │   (4Ω)        │
           └───────────────┘

⚠️ IMPORTANT: Adjust the MP1584 buck converter to exactly 5.0V using a multimeter before connecting to the ReSpeaker. The ESP32-S3 is not tolerant of overvoltage.

• Cube Main Body: Print upside-down (driver opening facing up)
• Cylinder Main Body: Print upright (feet on build plate)
• Top Plates: Print face-down for best surface finish
• Driver Baffle (cylinder): Print flat

1. Seal interior with acrylic spray for better acoustics
2. Add polyfill damping material (20-30g)
3. Use gasket tape around driver for airtight seal
4. Optional: Sand and paint exterior

1. Prepare buck converter: Adjust output to 5.0V, verify with multimeter
2. Mount amplifier: Secure TPA3116D2 to internal standoffs with M3 screws
3. Install power jack: Mount barrel jack in rear panel
4. Wire power: 12V to amp VIN and buck converter input
5. Wire 5V: Buck converter output to ReSpeaker 5V pad
6. Connect audio: 3.5mm cable from ReSpeaker to amp input
7. Install driver: Mount ND91-4 with gasket tape and M3 screws
8. Connect speaker: Amp output to driver (observe polarity)
9. Add damping: Place polyfill in acoustic chamber
10. Mount ReSpeaker: Place board in top plate pocket
11. Final assembly: Attach top plate with M3 screws

These enclosures are designed for use with ESPHome and Home Assistant.

The XIAO ESP32-S3 on the ReSpeaker boards can run ESPHome firmware for:

• Wake word detection (microWakeWord)
• Voice command processing
• Music playback via Music Assistant
• LED status indication

See the ESPHome documentation for:

• ReSpeaker Lite setup
• ReSpeaker XVF3800 integration

All designs are fully parametric. Key parameters to adjust in OpenSCAD:

// External dimensions
ext_width = 120;
ext_depth = 120;
ext_height = 145;

// Driver (change for different speaker)
driver_cutout = 86;
driver_od = 104;
driver_screw_circle = 95;

// Aesthetics
corner_r = 12;      // Corner radius
base_chamfer = 8;   // Base taper

1. Update driver_cutout, driver_od, and driver_screw_circle
2. Adjust enclosure volume if needed (sealed box calculator recommended)
3. Verify mounting depth fits within enclosure

├── docs
│   └── index.html                      # Visual comparison (interactive)
├── enclosure_lite_cube.scad            # ReSpeaker Lite - Cube
├── enclosure_lite_cylinder.scad        # ReSpeaker Lite - Cylinder
├── enclosure_xvf3800_cube.scad         # ReSpeaker XVF3800 - Cube
├── enclosure_xvf3800_cylinder.scad     # ReSpeaker XVF3800 - Cylinder
├── LICENSE
└── README.md

MIT License — feel free to modify and share.

• Seeed Studio for the ReSpeaker boards
• Dayton Audio for affordable quality drivers
• ESPHome and Home Assistant communities

Built to replace an Echo Studio with something open, customizable, and actually repairable.