Step by step assembly instructions (3D printed enclosure)
This section is work in progress!
The 3D printed enclosure provides a professional look to the device, while the material cost is not significantly increased. I used a BambuLab A1 with AMS to print the enclosure, but any 3D-printer that supports multiple fillament colors should be fine. In total less than 200g black and transparent PLA is needed. A handfull of M3 hex screws and heatinserts make it easy to assemble. There is now a large hole in the top of the cover for the buzzer. This ensures enough sound volume in large spaces. The bottom has 2 dovetail holes to insert feet or a wall mounting bracket.
The image below shows all the 3D printed parts: Front and Back Shells, 2X feet, 2x barckets to fix the LED 4x8x8 panel and 2x2 brackets the fix the 8x8 Lights panels.
First assemble the PCB. See detailed instructions I recommend that you don't use the USB-C input of the ESP32 development board, but feed the 5V directly to connector J4. Make sure the polarity is correct.
Add 4 STL files to your slicer and treat them as multiple parts of the same print. Select transparent filament for the "windows" and black (or any color you like) for the main body. Print the backets for the WS2812b panels (2x) and for the Led Text matrix. Insert the brass heat inserts using a dedicated tool (or soldering iron if you don't have one). Mount the main PCB using 4 M2 screws. Mount the Buzzer using 2 M3x15mm screws.
3D print the back shell. (only one color is needed). Depending on the accuracy of your printer, you may have to cut the M6-0.75 thread in the connector holes yourself. If you purchase a thread cutter, be aware that the tread is ISO-fine profile, meaning it has a pitch of 0.75mm. Insert the 7 connctors in the holes. Prepare the XH2.54 cable as shown in the picture. I use a small piece of heatshrink tube to cover the soldering lip:
Put the rings on the connectors and tighten the bolts. I have made a small tool to make fastening easy: Connect the cable to the main PCB.
Attention: The colors of the cable you are using may be different from the ones shown on the picture. Make sure you have the same order of connections to the pcb.
Insert the USB-C connector in the back and connect the cable to the main PCB.
Carefully combine front and backshells and insert and tighten the 4 m3x25 mm bolts.
Depending on how you will position the device (on a table sightly facing upward, or on an elevated platform against the wall facing slightly downward), select the right set of feet and print them. Insert them in the dovetail holes of the enclosure.