I wanted to build a voice assistant without cloud connection. For this I found the Rhasspy project which works really well. Sadly there was no case for my Pi 0 that did fit the Waveshare Audio Hat that I bought for this, so I had to design one of my own.

This design will fir the Pi Zero W and the Pi Zero 2. If you want to use Rhasspy without a base station, I recommend the Pi Zero 2.

I forgot to take pictures of the actual assembled version before adding the cover, I will upload them if I ever need to open this up again.

This design only fits one of the Speakers that comes with the Audio Hat, so the other one has to be removed. There is some space in the speaker top and the pi base that allows for the cable to pass through. The cable can be stored behind the Pi.

The Pi is attached to its plate with 2 M-2x5mm screws.
All plates are connected by 4 M-3x40mm screws.
The cover will stay in place without screws but make sure, everything works before adding it. It's a pain to remove, once it's in place.

Note to those, that want to use this setup with Rhasspy (docker). For the Rhasspy to find my sound card, I had to add the following at the end of my /etc/asound.conf

pcm.mic {
type plug
slave {
pcm "hw:1,0"
}
}
pcm.speaker {
type plug
slave {
pcm "hw:1,0"
}
}