Work in progress…

Louder-ESP32 Smart Speaker

ESP32-S3 + TAS5805M + Passive Radiators + TCP115 + DC28FT 

This project is a fully 3D-printed smart speaker designed around the Louder ESP32-S3 audio board (with built-in TAS5805M DSP power amp).
It delivers wide dispersion, strong bass for its size, and a clean aesthetic similar to modern smart speakers like the HomePod.

The enclosure is engineered to provide stiffness, low resonance, and excellent airflow, with optional active DSP or passive-crossover operation.

Enclosure & Dimensions

Internal volume: ~5–6 L

external size: 170 × 170 × 240 mm

Wall thickness: 5 mm

Rounded outer edges: R20 mm

Material: PLA+

Print orientation: top down

Fabric wrap: sleeve, retained between top/bottom grooves (TBC)

Optional outer shell: lamella cage for fabric support (TBC)

Driver Setup

Woofer

Dayton TCP115-4 (4" mid-bass)

Tweeter

Dayton DC28FT-8 (1-1/8" dome, truncated faceplate)

Mounted above woofer for vertical 2-way alignment

Passive Radiators

2× Dayton DMA105-PR

Mounted left/right side for symmetric bass pressure and reduced rocking motion

Internal Structure

To achieve a rigid, low-resonance enclosure:

Vertical spine: runs front-to-back, controlling “breathing” mode

PR strap brace: ties left/right walls at PR height

Ribs on top/back: 3–3.5 mm thick; suppress panel resonance

Radial PR ribs: 5–6 spokes around each PR to distribute forces

Driver doublers: reinforcement behind woofer, tweeter, and PR cutouts

Corner fillets everywhere for strength and printability

Fabric Wrap System

coming soon

Electronics (Louder32 ESP32-S3)

ESP32-S3 Wi-Fi streaming + control

TAS5805M 2× digital-input Class-D amplifier

Mounts on back wall using four M2.5 standoffs

Compatible with:

Snapcast

Squeezelite-ESP32

Printing Guidelines

Walls: 5 perimeters

Top/bottom: 5 solid layers

Infill:

Enclosure: 12–15% Gyroid or Adaptive Cubic

Baffle + PR areas: 25–40% (modifier)

DSP / Audio Tuning

Two paths:

Active DSP (recommended)

Coming Soon..

Using custom TAS5805M firmware:

LR4 crossover @ 2.6–2.8 kHz

Woofer shaping EQ

Tweeter EQ & level trim

PR subsonic HPF (~30 Hz)

Optional limiters for protection

Passive crossover (simple option)

If not using DSP:

2.5–3.0 kHz LR2 network

L-pad for tweeter

Air-core inductors + film capacitors

Stuffing & Damping

Recommended internal damping:

Polyfill / polyester fiberfill

Light–moderate amount (~20 g)

Keep PR areas clear by 20–30 mm