10" tall Bluetooth AirPod - 3D Printed

Last crawled date: 1 year, 12 months ago

This model is provided for entertainment purposes only. It is not my intention-nor do I have authorization to-copy Apple's original design for their wireless earbuds.

As seen online! https://www.businessinsider.com/airpod-apple-bluetooth-speaker-photos-minnesota-high-school-student-2019-11

This is a larger-than-usual left ear AirPod "clone". It's... large, not very portable. Included are STEP and STL files for both the large Bluetooth version, as well as a blank model of 1:1 scale AirPods too. Credit me if you make one online! You can also print 1:1 fakes with the provided solid model.

If you want to build the large Bluetooth one, you'll need:
- Access to a 3D printer (20x20cm build size)
- 22-30ga wire (for extending the wires to the speaker, buttons, and battery)
- 3 push buttons - https://www.adafruit.com/product/367
- This Bluetooth speaker - https://www.amazon.com/gp/product/B07JFK95ZD/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1
- Window screen for the speaker + mic meshes

After printing all three parts, the screen for the meshes can be glued in from the inside of the AirPod for two of the holes. For the main speaker hole as well as the bottom hole (mic on an actual AirPod), the screen should be cut precisely to that size and then glued in. It's not an easy process, but if you are careful to glue only the edges, it doesn't look too bad.
Disassemble the Bluetooth speaker by undoing the visible bolts (with a 2.5mm allen key). The inner screws are phillips head, and after the case is open, all components can be removed pretty easily. To remove the speaker, cut around the plastic, basically cutting it out of the case. This requires a good pair of some cutting tool (a dremel would work too).
Carefully cut or desolder the buttons from the PCB, and solder 9-12" wires to three new (or reused) buttons, but KEEP ONE SIDE DISCONNECTED until the wires are threaded through the "base" piece of the AirPod. The battery needs similar length wire, and the speaker needs ~4" wires.
The speaker should be glued into the "head" piece, and the PCB screws into the "base" piece with the MicroUSB port upside down, lined up with the charging hole on the side of the AirPod. The battery is put in from the bottom. The buttons get glued in place on the silver piece/print, and their wires should go all the way through the AirPod. This is a bit difficult to fit in beside the battery cables, but with some time it's possible.
For the black spots on the outside of the AirPod, I painted them on and put epoxy over it to make it glossy, but that's not necessary if the paint doesn't rub off on its own. The "head" piece will slot into the "base", but be careful when doing so, since the tabs are tiny and break off quite easily.

Inspiration for this project came from u/DangDan12's AirPod post a while ago. AirPod surface model credit goes to the creator of this model (although it is heavily modified to look like the original AirPods, and not like a fake Chinese clone): https://grabcad.com/library/apple-airpod-earphone-case-1