Squeezeboxen Case V1 (V2 coming soon)

Here's a preview of V2:

Squeezelite-ESP32 player (with 2 DAC options: PCM5102 & ES9018), Max9744 amplifier, VU meters. There's also a spectrum analyser and SqueezeAMP box in the works with the same styling.

The main changes are to the aspect but the mounting boards now have slots for zip ties and the rear panels are improved. The feet are also deeper to allow better locating when stacking.

Intro:

Since the demise of Squeezebox, a number of alternatives have sprung up with most concentrating on the integration of the internals. Here is my first attempt at creating a template that caters for many of the hardware and software variations and providing 2 different combinations in a small but aesthetically pleasing form factor.

I've made a number of PiCorePlayer based streamers in the past and the design was originally catered towards this and based around a RPi 3A:

During the design I was made aware of the Squeezelite-ESP32 project and decided to give it a try. It worked with the same hardware but I thought it would benefit from a different display, which led to the second variation:

Due to the huge number of third party hardware available, and the various combinations, I cannot cover them all but I have included the original FreeCAD design file and exported all components as STEP files for modification, including a blank version of the ends.

For fine tweaking tolerances, the FreeCAD file has a spreadsheet with the main dimensions in but even so, the variation in 2 displays of the same brand and type was significant enough for me to have to make adjustments. A case in point is that the SSD1322 display is such a tight fit that I never ended up using any screws to mount it.

Printed Parts:

The main parts are:

• Shell

This is the main body. I would recommend printing this in PLA+ (annealed) or ABS, or another material that will not heat creep over time. 

• Front & clamp

These hold and clamp the display and IR sensor. Also the rotary encoder and power button in the version with these.

• Rear & shield

These provide access for the various inputs and outputs. The shield provides additional support for a USB power supply connector for the RPi version and is optional for the ESP32 version but does allow a more aesthetic appeal by reducing the size of the holes.

• Trays

These support the internals and are mounted to the inside of the shell.

• Inserts

These are aesthetic features but can be removed to implement stacking multiple components.

Feet (See above)

These are functional and should be printed in something like TPU to help prevent slipping.

• Dial/Knob

I'm relatively knew to FreeCAD and wanted a knurled control knob so resorted to OpenSCAD, which I am much more comfortable with. I printed this on a Mini with a 0.25mm nozzle. For modifying the OpenSCAD code, the BOSL2 library needs to be installed. An STL file is included since OpenSCAD doesn't export STEP files.

Electronics:

• ST7789 Display.
• 3.12" SSD1322 OLED Display (AliExpress)
• USB breakout 

• Rotary Encoder

• 16mm Power button with LED

•  Vishay TSOP4838 Infrared Receiver 38kHz
• ESP32 Wrover and ESP32 DEV board

• PCM5102 board

BOM (Apologies - this was compiled post build and may need revision)

Unfortunately, there are a number of heat-set inserts needed (M3x4x5):

• 8 in the main shell for attaching the ends.
• 4 or 5 in the front (4 for the display and one for the IR clamp for the SSD1322 display)
• 4 in the tray plus another 2 in the PCM5102 tray (Side mounted)

Square nuts - these are used to attach the insets to the shell and the shields to the rears. 

• 16 M3 square nuts.

Button head screws are used for aesthetics.

• 16 M3x8 button head screws for the inserts.
• 8 M3x10 button head screws for the front and rears.
• 8 M3x6 button head screws for the shields.
• 2 M3x16 button head screws for the PCM5102 mount (since it is mounted through a side insert via a spacer).

Some self tapping screws.

• 6 M2.5x6 self tapping screws for the RPi mount and the USB power socket.
• 4 M3x12 socket head screws for the feet.

Socket head screws for functional but hidden parts.

• 4 M3x6 socket head screws for ST7789 clamp
• 4 M3x4 socket head screws for SSD1322 clamp
• 1 M3x6 socket head screw for SSD1322 IR clamp

Note: The SSD1322 fit very tightly in my case and I didn't use any screws in the end. Alternatively, some self tapping screws could be used but the holes may need to be reduced.

Printing Parameters:

I deliberately made the walls thick to give it a more substantive feel. I also used quite dense infill to this end and printing parameters adopted from the Voron PIF program, namely:

• 0.4mm extrusion width (forced for all)
• 4 perimeters
• 40% infill (cubic)

All of this should be printable on the Mini with the possible exception of the TPU feet. I used a MK3S for the feet but please remember to use a debonding agent to prevent ruining your PEI sheet.

Front, rear and inserts were printed on a textured sheet to hide print lines and give a nice finish (Silky filament also helps here).

I used:

• 3DQF Deep Black PLA+ for the shell.
• Overture Copper Silk PLA for the front, back and inserts.
• Overture TPU (95A) for the feet.
• 3DQF PLA in various colours for all other parts.

Notes:

Going forward I want this to become a common design for a range of components that can be stacked. These include a class D amplifier, LMS server, power distribution, visualisation module and possibly even speakers. I also want to split the DAC from the RPi/ESP32 but need to figure out how to tap into the I2S stream to show the bit-rate on a small segment display.

Given that the SSD1322 version was originally unintended, it ended up being a tight fit without making the dust shield/interface walls thinner. Consequently, the overall dimensions may change slightly with Version 2 onwards. This may also be necessitated by some of the other electronics used in the future.

My preferred platform has shifted to Squeezelite-ESP32, which therefore excludes larger displays as well as those with touch control. However, I also aim to produce at least one touch-screen based system as a more personal headphone player but that will be a different project entirely and based on the RPi. PiCorePlayer doesn't seem to have had any development recently but other options are emerging, e.g. Moode, but these require higher spec hardware and will not load entirely into memory the way PiCorePlayer does, so will be at the mercy of shutdown procedures. PiCorePlayer is still an excellent option and more easily leverages the huge 3rd party catalogue of audio hats. Meanwhile Squeezelite-ESP32 is currently under active development and there are options for bespoke hardware such as SqueezeAMP.

There are a lot of 3rd party DAC hats available for the RPi, many of which can actually be used with the ESP32. Unfortunately I have a very limited budget so will be unable to experiment with many of them, particularly those from ALLO and HiFi Berry. 

License:

I have licensed all files included here under the CC BY-NC-SA 4.0 license. I run a small social enterprise geared towards helping adults with autism and other cognitive disorders gain access to 3D printing as a form of personal development and mental health support, and therefore reserve the right to monetise the designs to aid this venture.

The files are free to use for personal use but please understand the terms before downloading any files. The share-alike component of this license is particularly important for those intending to remix.