This is a complete enclosure for an ICEpower 50ASX2SE Class D Audio Amplifier module, a 50W stereo amplifier (45W/channel 4 ohms) board made by the Danish company Bang and Olufsen. (Not to be confused with some of the far east "50W" amplifier boards on the market). Until recently, ICEpower modules were not sold to the general public but only to equipment OEMS. Parts Express company now sells the boards, so here's how you can make a very high quality hifi stereo amplifier with quite little soldering and the help of your 3D printer. 200mm x 150mm or larger print bed required.
I needed a small but powerful and high quality stereo amplifier for an installation I was doing, and remembered these modules now being available. The ICEpower modules do not require heat sinks nor a grounded chassis (the board contains the AC power supply, which is double insulated), so a 3D printed enclosure seemed like the obvious and easiest choice. This arrangement printed perfectly first time, but was designed and built using some connectors I already had on hand. For this posting, I went back and modified the audio connector mounting hole sizes for use with more easily obtained parts.
The enclosure consists of a bottom part and a top part, both well vented. The board mounts into the bottom using 4 sheet metal or self-tapping screws. There is also an STL for plastic feet also installed with the same type screws (rubber feet from a hardware store could be used instead if you want something with more friction). The top attaches to the bottom using four of the same type screws.
This is the parts list for the amplifier:
A) The amp board is Parts Express# 326-212
B) The input connectors are PE# 091-1120 (one set needed)
C) The output binding posts are PE# 320-3375 (one set needed)
D) the IEC AC power connector is 090-442
E) wiring can be bought as wiring harness kit PE# 326-150 (one needed)
F) assembly screws are #6x3/8" sheet metal screws (12 needed) [metric: M3 or M3.5x10]
G) #4-40 x 3/4" screws, lockwashers, nuts.(2 sets) [metric: M3 x 15mm]
For the build shown, I used connectors at hand, rather than the ones in the part list (I'm also including the STL file for the case version with holes for mounting those in case that works better for you). [The input connectors in that version were CMC 816U, and the output binding posts were larger ones that mount on a 13mm hole.] I modified that file to use more easily obtained connectors to make the suggested bottom part file.
This is a pretty simple print, would probably be ok without supports (though I used supports when I printed). Also pretty simple assembly, just a few minutes to drive in some screws, maybe half an hour to cut, strip and attach the ends of the wiring harnesses to the connectors. The amp works great and has plenty of very quiet, clean power for most high fidelity loudspeakers.
I used 0.25mm (0.4mm nozzle). Depends on appearance desired. Should work fine with 0.38mm (0.6mm nozzle)
Hand drive all the screws in and then back out to loosen up holes before final assembly. Do not over-tighten the top-to-bottom screws, only till the top fits snugly.
Make sure you put the jumper on the ICEpower board to match the AC voltage (110V or 220V) in your area!
A rather quick design in Fusion360 (after a not-so-quick model of the ICEpower board itself). The enclosure was done base on form-following-function, I resisted the urge to gussy it up with fake heatsinks, logos, lightning bolt holes, etc.! If you want to take it from here, or make changes for other connectors, the F360 model is here:
The ICEpower module model STL is also included (but, obviously, for enclosure design, not for printing by itself).