Passive Speaker.

The following Instructable is to learn how to create a passive speaker, with some laser cut polypropylene in a few steps. You will need access to a laser-cut, use the file provided, some colored threads, and a glue gun!

NOTE: The speaker has been designed for a MI MIX 2S, with the dimensions shown on the drawing.

Download the laser cut files. Set up to 0.01mm weight and RGB color. Red for cutting, blue for engraving.

Once you have all the pieces, put them all in order, to make easier the assembly. Also, check if there is any imperfection and remove it with a cuter.

TIP: Place them in the direction they are going to be assembled.

The inside structure of the speaker consists of three main parts: the upper part, and the side parts, that are symmetric.

The easiest way is to start to assemble the upper part and then add the side parts.

The base part, has engraved the placement of each piece. Put some hot glue to fix the pieces and make the internal part more resistant. Also, it is going to be easier to assemble the rest of the parts.

These parts are the ones that cover the interior of the speaker to avoid the sound to bounce in the notched structure.

As can be seen in the picture, this part is composed of 3 pieces, connected by a slot system. Follow the photos to assemble it properly.

In this step, we will need the cover, the two exterior parts, and the threads. In this particular case, I have used 4 different thread colors.

First, sew the cover, with just one of the side parts. To know where to start, center the piece, and avoid the center hole, the one aligned with the centerline, as it can be seen in the photos. Once we have the first side, without making a knot on the front, start to sew the second exterior part. The final result, should be the external parts sewed but living the assemble open on the front and the back.

TIP: Use some hot glue to avoid the thread to unravel. Put some on the ending. Also it is a good idea to place a bit on the knots to make them more strong.

Once you have the cover and the external parts sewed, insert the interior part to the structure, cover it with the sewed assembly and use the remaining thread to sew the assembly with the endings of the internal apart, as it can be seen on the first photo.

Having the cover fixed with the internal structure, start sewing the opened back, and move to the front.

Finally, make a strong knot between the threads used to sew the cover and the internal part, with the ones that sewed the base to the rest of the assembly.