Dual Ported Enclosure Speaker (Dayton PS95-8)

I wanted to build my sister a simple, aesthetically pleasing, and great sounding pair of speakers for her living room. I found this ported enclosure for the Dayton PS95-8 full-range drivers by @ProjectsByBrian, and loved the design. 

However, I figured the relatively small (3.5") PS95 might struggle with overall output for midfield listening, such as in a living room, especially without a subwoofer. Therefore, I decided to remix his enclosure design to accommodate two of the PS95 in a vertical arrangement. I also added a stand/plinth for the speakers to sit on, and cable routing to connect the two drivers together and route the cable down and out of the back of the stand. And finally I added heat set insert holes for 4 M4x4x6 heat set threaded inserts to hold the driver in the baffle.

With two of the same driver, this should result in a +3-6dB increase in total output, and could also have other positive effects such as lowering distortion, though I have not yet measured them to compare.

I printed the bottom enclosure and stand as one piece, and the top enclosure as a separate piece in a contrasting color. The bottom piece was printed on the Bambu P1S in PLA Meta, and the top piece was printed on the Qidi Q2 with PLA Silk+, both with 0.4mm nozzles. Both parts turned out great using tree supports, and I really love the overall look of the speaker. Each part was ~400-500g of filament, so it worked perfectly to build a pair with 1kg of each material, and each part took around ~12h to print. I printed with 3 walls and 10% gyroid infill with tree supports.

The top piece has a circular extension that slides into the bottom enclosure and allows it to stack on top. I added some hot glue between the two pieces to hold them together more strongly and prevent rattling between the enclosures.

I think these speakers could work well with just a single 560uF non-polar capacitor working as an 80hz high-pass filter for the drivers. However, since the amplifier that will be used to power them (the SMSL A300) has a built in 80hz digital high-pass filter, I simply connected the speakers directly to the amplifier and enabled the high-pass filter, so in my case these speakers actually require no analog crossover!

These speakers sound really great, especially given their size and cost, and they have a very unique and interesting look. There is a lot to love about these little speakers and I think my sister will be extremely happy with them for her living room. They will certainly be a huge improvement over her built-in TV speakers! And a huge thanks again to @ProjectsByBrian for the original enclosure design!