Introduction
Turning an idea into a physical product has never been faster or more accessible. In this blog, we take you behind the scenes of one of our favourite in-house projects — the credit card-sized Bluetooth speaker.
The Concept
The idea was born from a need for ultra-portable sound combined with a sleek design. We envisioned a Bluetooth speaker the size of a business card that could also share digital contact info via NFC.
Design & Prototyping
- Sketching: Early sketches explored layout, speaker placement, and battery integration.
- CAD Design: We used Fusion 360 to create precise dimensions, mounting points, and electronics housings.
- Prototyping: Multiple versions were printed using PLA and PETG, with revisions made to optimise sound output and screw placement for panel interchangeability.
- Testing: We tested audio quality using salvaged iPhone speaker drivers, NFC functionality, and panel durability.
- Iteration: Each version improved airflow, bass resonance, and component access until we achieved the perfect balance.
The Final Product
The finished speaker is 85x55mm and features an interchangeable face panel design held by four screws, customisable branding, built-in NFC tag, USB-C charging, and stereo pairing capabilities.
Conclusion
This project shows how 3D printing supports rapid ideation, prototyping, and full production. From concept to creation, 3DCustomPrint helps ideas become tangible products.