Desktop Intercom Enclosure

ESPHome Desktop Intercom Enclosure (“Loaf” Style)

A dedicated desktop enclosure designed for ESPHome-based smart intercom nodes. Featuring a retro-modern “loaf” profile with a curved front-to-top edge, this 3-piece housing gives your DIY smart home project a polished, commercial look on any desk or shelf. 

The front grille is designed as a separate insert, making it simple to print in a contrasting color for a sleek two-tone aesthetic without needing a multi-material system. 

Key Features

3-Piece Modular Design: Includes the main outer shell, a separate perforated front grille insert, and a screw-on bottom base plate. 

Two-Tone Aesthetics: Print the grille insert in a accent color to match your setup. 

Hidden Hardware: Bottom assembly screws sit in countersunk recesses that are completely hidden once stick-on rubber feet are applied. 

Acoustic & Cable Layout: Includes a top-facing port for a microphone and a rear pass-through hole aligned for ESP32 USB power. 

Required Hardware & Electronics

Speaker: 42 mm speaker (34 mm mounting hole pattern) 

Microcontroller: ESP32 development board (25.4 mm x 50 mm mounting hole pattern) 

Microphone Module: Mounted internally under the top mic port 

Fasteners: Small M3-equivalent self-tapping screws 

Adhesive: A small amount of glue (or superglue) to secure the front grille insert 

Feet: Stick-on rubber feet (fits inside the bottom screw recesses) 

Assembly Instructions

1. Mount the Speaker: Screw your 42 mm speaker onto the standoffs located on the back of the grille_insert. 

2. Install the Grille: Press and glue the grille_insert into the front window recess from the inside of the shell. 

3. Mount the ESP32: Screw your ESP32 board onto the standoffs located on the bottom_plate. 

4. Wire & Test: Complete your wiring between the ESP32, microphone, and speaker. 

5. Close the Case: Screw the bottom_plate to the shell corner posts from the underside. 

6. Finish: Apply stick-on rubber feet over the countersunk screw holes on the bottom plate. 

Print Settings

Orientation:

shell: Print rim-down (open side on the bed). 

grille_insert: Print front-face down (standoffs pointing up). 

bottom_plate: Print flat on the bed. 

Supports: Generally not required if your printer handles reasonable bridging for the internal overhangs.

Infill: 15%–20% (Grid or Gyroid).

Walls/Perimeters: 2 to 3 perimeters (designed around a standard 2.5 mm wall thickness).