Audio Source Switch and Volume Control Boxes

prusaprinters

3D Printed Audio Source Switch and Volume Control BoxesDOWNLOAD Version 1.4 (2022-08-04) ZIP ~16MBINTROBelow you will find parts and tools, which will help you to print and assemble audio source switch and volume control boxes. If you noticed mistakes, have questions or suggestions, know better component (available in EU and US), please write or send link to info@jocys.com • Project page: Jocys.com/SwitchParts were printed from PETG with Prusa3D i3 MK3 Printer. If your printer is not precise enough, printed parts may not fit into each other and may not look good.If you made your own updates or (file) changes, related to this project, please send me a link. I will add this link to your work on this page.Why I decided to make my own switch? I tested few audio switches. Ground wires of both audio sources were connected together in all of them. Why? I understand, that manufacturers can save few € by using cheaper switches with fewer poles, but consequences of that are unacceptable. Unnecessary ground merging creates audio noise and anomalies. You need to buy and use ground loop isolators to eliminate this noise, but ground loop isolators degrade quality of the audio slightly. I wanted audio to go through ground loop noise isolators ONLY, when both audio sources are merged (when you want to hear audio from both computers at the same time). To avoid audio merging, while switching sources, I used non-shorting switches. Also, I wanted to switch headphones and stereo microphone with ability to switch off (disconnect) microphone completely. With stereo microphone you can have better environment noise elimination options in software. I didn’t want to use powered audio mixers or interfaces, which needs power and processes (distorts) signal in any way.Features:1. Microphone switch: PC1 • OFF • PC2.2. PC1 audio volume control.3. PC2 audio volume control.4. Audio source switch: PC1 • PC2.5. Audio source merge: PC# (OFF) • PC1 + PC2 (ON) - audio signal grounds of PC1 and PC2 are merged and audio goes through ground loop noise isolators ONLY, when audio signals are merged. This allows to avoid audio quality degradation, when unnecessary and you don't need to listen both computers at the same time.UPDATES1.4 (2022-08-04) • 35° angle connector added.1.3 (2022-08-02) • 35° angle adapters added.1.2 (2022-07-31) • Large and medium boxes removed. Small box and knobs updated.1.0 (2020-06-06) • Released1.1 (2020-06-09) • Smooth shaft button added, knurled removed. Knobs redesigned to hide screw hole and to reduce ZIP from 67 to 11 MB.0.1 (2020-04-25) • ...PARTSPARTS WITHOUT TOOLS AND DELIVERYTOTAL€1202022-08-04Mouser€20Audio switches, potentiometers for volume controlFarnell€263.5mm jacks socketsKenable€73.5mm cablesNeoteck€28Ground loop isolators12voltplanet€80.5mm² 11A cablesAffixit€6Bumper stopsAccu€5Cup point grub screws and nuts for knobsAmazon / MCPP BasicFill€200.8 kg PETG 3D printer filamentROTARY SWITCH FOR AUDIO SOURCE SWITCHINGFind on Mouser (EU) • Digi-Key (US)2 x Taiwan Alpha • SR2511F-0602-19R0B-E9-N-W-159Rotary switch with 6 poles and 2 positions for "Audio Source Switch" and "Audio Merge Switch" boxes.I would not recommend to buy cheap Chinese rotary switches. They are, usually, made from softer metal and after several dozen switches lose switching smoothness.Series: SR2511FProduct Category: Rotary SwitchesNumber of Positions: 2 PositionNumber of Decks: 1 DeckNumber of Poles per Deck: 6 PoleCurrent Rating: 300 mAVoltage Rating AC: 125 VACIndex Angle: 0 degContact Style: Non-Shorting (Non-Shorting / Break-Before-Make)Termination Style: Solder LugThread Size: M9xP0.75 (9mm)1 x Taiwan Alpha • SR2511F-0403-19R0B-E9-N-W-159Find on Mouser (EU) • Digi-Key (US)Rotary switch with 4 poles and 3 positions for "Microphone Switch" box.I would not recommend to buy cheap Chinese rotary switches. They are, usually, made from softer metals and after several dozen switches lose switching smoothness.Series: SR2511FProduct Category: Rotary SwitchesNumber of Positions: 3 PositionNumber of Decks: 1 DeckNumber of Poles per Deck: 4 PoleCurrent Rating: 300 mAVoltage Rating AC: 125 VACIndex Angle: 0 degContact Style: Non-Shorting (Non-Shorting / Break-Before-Make)Termination Style: Solder LugThread Size: M9xP0.75 (9mm)ROTARY POTENTIOMETER FOR VOLUME CONTROL2 x Bourns • PTD902-1015K-A102Find on Mouser (EU) • Digi-Key (US)Sennheiser uses 500Ω potentiometer in HZR 62 volume control for HD 62 TV 32Ω headphones. Creative uses 1000Ω (1KΩ) potentiometer in Volume Control Module for Sound Blaster Zx. 10000Ω (10KΩ) potentiometers are too strong for Sennheiser HD 598 50Ω headphones.Bourns rotary potentiometer for volume control box.Series: ProAudio PTD90 (9mm)Resistance: 1 kOhmsTaper: AudioNumber of Turns: 1 TurnNumber of Gangs: 2 GangElement Type: CarbonTolerance: 10 %Thread Size: M7xP0.75 (7mm)Shaft Type: Knurled / SerratedShaft Diameter: 6 mmShaft Length: 15 mmTermination Style: Through HoleMounting Style: Panel MountLife: 15000 CyclesPower Rating: 25 mWVoltage Rating: 20 VDC, 150 VAC3.5MM 3 POLE JACK SOCKET16 x EST Marushin • MJ-073HFind on CPC Farnell • UK Farnell • US Newark )3.5mm 3-Pole Panel Mount Jack SocketManufacturer Part No: MJ-073HNo. of Contacts: 3 ContactsGender: SocketPin Diameter: 3.5mmConnector Mounting: Chassis MountContact Plating: Gold over Nickel Plated ContactsConnector Body Material: Plastic BodyDIAGRAMS5 Small Boxes Switch Box Diagram1 x Taiwan Alpha • SR2511F Rotary Switch 4 Poles 3 Positions1 x Taiwan Alpha • SR2511F Rotary Switch 6 Poles 2 Positions2 x Bourns PTD902-1015K-A102 Potentiometer16 x EST Marushin • MJ-073H 3.5mm 3 Pole Jack Socket2 x Neoteck Ground Loop Noise Isolator5 x Kenable • 001454 3.5mm Jack to Jack 15cm CableVolume Control Box DiagramIn this photo volume box assembled with 1 IN and 2 OUT (split) sockets.1 x Bourns • PTD90 Rotary Potentiometer2 x EST Marushin • MJ-073H 3.5mm 3 Pole Jack SocketAUDIO CABLES5 x Kenable • 001454 3.5mm Jack to Jack 15cm CableFor connections between boxes, ground loop isolators.1 x Amazon • 3.5mm Audio Jack Extender 3 inch (7.6mm)If you will use "Volume Control" box attached to a leg table, I would recommend to use short 3.5mm Audio Jack Extender for some time. If you will forget, that you are wearing headphones, and will move from the table... if "Volume Control" box will not disconnection from its holder, extender will bend and headphones will disconnect first.GROUND LOOP NOISE ISOLATOR2 x Neoteck • Ground Loop Noise IsolatorIf you will use "Audio Source Merge" box (to hear both computers at the same time), grounds of booth sources will be connected together. This can introduce background audio noise and anomalies. To avoid problems, you need to add Ground Loop Noise Isolator between "Volume Control" and "Audio Source Merge" boxes for BOTH computers..Eliminates Hiss, hum, and other background interference, caused by ground loop noise.For any audio devices that has 3.5mm audio jacks, like car audio system, home stereo, PC, laptop, speaker.Compact size makes it easy to carry around.Easy installation, no extra setup. All you need to do is to plug it in.Contents: Vinteam ground loop isolator, 3.5mm audio cable, user manual, 18-Month product replacement warranty.CABLES12voltplanet • Single 0.5mm² 11AI cut majority of wires into 7cm length pieces. Then stripped insulation from the ends (3mm for 3.5mm audio jack and potentiometer pins, 1mm for switch pins). I created few longer wires to connect 2 or 3 pins together at one of the ends (cutting example).1 x 50m Reel of Single 0.5mm² 11A - Black (ground)1 x 50m Reel of Single 0.5mm² 11A - Red (right)1 x 50m Reel of Single 0.5mm² 11A - White (left)Manufactured to: ISO 6722:2006 (Class B)Voltage rating: suitable for 12V & 24V systems (60V max.)Nominal current rating: 11AMaximum loading: 132W@12V, 264W@24VNo./size of conductors: 16/0.20mmConductor cross section: 0.5mm2Maximum overall cable diameter: 1.7mmResistance per m at 20oC: 0.0371 ΩConductor material: Plain copperInsulation material: PVC (hard grade)Working temperature range: -40oC to +105oC (with brief excursions up to +120oC) BUMPER STOPS14 x BumperStops • Affixit • Cylindrical Bumper Stops PD.2120BSHEETPD.2120 Cylindrical Bumper stops - 10.1mm x 1.8mm288 Bumper Stops per Sheet (Priced per Sheet)Material: PolyurethaneAdhesive: Black Bumper stops have a Rubber Adhesive.Service Temperature for Black Bumper stops: -20 °C to 70°CAnti SlipAnti ScratchAnti VibrateAbsorbs ShockDampens SoundSCREWS AND NUTS FOR IKEA OLOV LEG HOLDER3 x Accu • M3 x Cap Head Screw (DIN 912)M3 12mm Cap Head Screws for IKEA OLOV adustable leg holder.M3 (3mm) Thread Size (T)12mm Length (L)3mm Head Length (H)1.3mm Hexagon Depth (P)2.5mm Hexagon Socket A/F (J)DIN 912 Manufacturing Standard+/- 0.13mm General TolerancesYes Fully Threaded12.9 Hardened Steel Material0.5mm Screw Thread PitchSelf Colour Finish5.5mm Head Diameter (D)10mm or 18mm Thread Length (Max)3 x Accu • M3 Hexagon Nut (DIN 934)M3 Hexagon Nuts for IKEA OLOV adustable leg holder (3).DIN 934 Manufacturing Standard5.32mm - 5.50mm Nut Width A/F (F)0.13mm General TolerancesA4 Stainless Steel - Black MaterialA4 Stainless Steel Material SpecificationChemical Matte Black Finish6.01mm Nut Width A/P (C)0.5mm Thread PitchM3 (3mm) Thread Size2.15mm - 2.40mm Nut Thickness (T)SCREWS AND NUTS FOR SWITCH KNOBS3 x Accu • M3 8mm Cup Point Grub Screw (DIN 916)M3 8mm Cup Point Grub Screw for knobs.Cup Diameter: 1.15mm-1.4mmFinish: Chemical Matte BlackLength: 8mm Manufacturing Standard: DIN 916Material: A4 Stainless Steel (Black)Min Socket Head Depth: 1.2mmPitch: 0.5mm1.5mm (1.52mm-1.58mm) Hexagon Socked (1)Thread Size: M3 (3mm)3 x Accu • M3 Square Nut (DIN 562)M3 Square Nuts for knobs (1).Finish: Chemical Matte BlackManufacturing Standard: DIN 562Material: A4 Stainless Steel (Black)Pitch: 0.5mmThickness: 1.8mmThread Size: M3 (3mm)Width: 5.5mmKNOBS (OPTIONAL)Kilo International • OEJA-90-4-5 KnobThese knobs look good for volume control. Make sure, shaft diameters on knob and potentiometer are the same (6mm or 6.35mm).Model: OEJIndicator: (L)line, (A)arrow, (NI)no ind.Diameter: (50)0.500", (63)0.625", (75)0.750", (90)0.920"Finish: (1)clear gloss, (2)black gloss, (3)clear matte, (4)black matteShaft Size: (5)0.250"(6.35mm), (6)0.125", (7)0.2375"(6mm)VELCRO (OPTIONAL)Velcro • One-Wrap Reusable Ties 10mm x 5m10mm x 5m - Black - For tying Volume Box B to something with "Volume Control Box B Bottom" part for Velcro.Velcro • Heavy Duty Stick On Tape 50mm x 1m50mm x 1m - Black - For sticking Volume Box B to something with "Volume Control Box B Bottom" part for Velcro.VELCRO® Brand Stick On fasteners are ideal for smooth surfaces and can be used indoors or outside. They are available in squares, coins, strips, and tapes and come in a range of colors.1. Clean and dry surface before application2. Peel tape from fastener and press firmly into place3. Adhesive reaches maximum strength after 24 hoursTOOLS3D PRINTERPrusa • i3 MK3 3D Printer• Print technology: Fused Filament Fabrication / Fused Deposition Modeling.• 0.4mm nozzle (easy changeable) for 1.75 mm filament.• Build volume 11,025 cm3 (25 x 21 x 21 cm).• Layer height (layer resolution) from 0.05 mm (50 microns).• Accuracy: 0.01 x 0.01 x 0.005 mm (10 x 10 x 5 microns).• Max extruder temperature: 280 °C.• Max heated bed temperature: 120 °C.• Supported materials: PLA, ABS, PET, HIPS, Flex PP, Ninjaflex, Laywood, Laybrick, Nylon, Bamboofill, Bronzefill, ASA, T-Glase, Carbon-fibers enhanced filaments, Polycarbonates...SOLDERING TOOLSWeller • BP865CEUWeller • PU 81For soldering wires to potentiometer and switch.Weller • Tip-ActivatorFor regeneration of oxidized tips. Cleaning only possible in hot state of the soldering tip.Weller • WP 65 SetWP 65 - Soldering iron 65 W, 24 V with Power-Response Heating Technology.XNT A - Soldering tip chisel 1,6 x 0,4 mm.WDH 10 - Safety rest with Stop+Go function and dry cleaner.Weller • EL60/40-100Kester • 44 Flux-Cored WireSn60Pb40 - 0.8mm - 3.3% Flux - melting range 183-190°CSn63Pb37 - 0.8mm - 3.3% Flux - melting point 183°CSCREWDRIVERSWera Tools • Series Kraftform Micro 2054 (05118066001)For M3 cup point grub screws on knobs (DIN 916).2054 Screwdriver (1.5mm) for hexagon socket screws for electronic applications.High-quality steel micro screwdriverHex-Plus allows socket head screws to live longerPower zone with integrated soft gripFree spin capAnti-roll offCorrosion protectedChemical resistanceWera Tools • Series Kraftform Micro 2054 (05118070001)For M3 cap head screws (DIN 912) for IKEA OLOV adustable leg holder.2054 Screwdriver (2.5mm) for hexagon socket screws for electronic applications.High-quality steel micro screwdriverHex-Plus allows socket head screws to live longerPower zone with integrated soft gripFree spin capAnti-roll offCorrosion protectedChemical resistanceWIRE STRIPPING AND CUTTING TOOLSC.K Tools • 495001 Wire StripperStripping: 0.2 - 6.0mm²;Cutting: HRC 40 - 50;Crimping: 0.5 - 6.0mm² insulated and non-insulated terminalsC.K Tools • Wire Stripping Pliers T3894For safe and damage-free stripping of fine, insulated solid wires. Suitable for cutting soft copper wires.Stripping capacities mm: 0.4, 0.5, 0.6, 0.8, 1.0, 1.3Stripping capacities AWG: 26, 24, 22, 20, 18, 16C.K Tools • Side Cutters T3887Precision side cutters. Suitable for cutting soft copper wires of up to 1.6mmØ / 14AWG.PETG FILAMENTI would not recommend to print parts from ABS (shrinkage is too big) or PLA (low heat resistance).I had no problems with these filaments:Prusa3D • Jet Black Prusament PETG 1.75MCPP • BasicFil Black PETG 1.75Amazon • AmazonBasics Black PETG 1.75PC Johnson • Windex Original Glass CleanerFor preparing-cleaning heated printer bed... Spring Steel Sheet with Smooth Double-sided PEI before printing with PETG filament.Water: WaterCleaning Agent: 2-Hexoxyethanol, Isopropanolamine, Ammonium HydroxideWetting Agent: Lauryl Dimethyl Amine Oxide, Sodium Dodecylbenzene SulfonateFragrance: FragranceDye: Liquitint® Sky Blue DyeSHL • Isopropanol / Isopropyl Alcohol / IPANOTE: I didn't test-print parts for this project on Textured PEI Powder-coated Spring Steel Sheet.For preparing-cleaning heated printer bed... Double-sided Textured PEI Powder-coated Spring Steel Sheet before printing with PETG filament.For thin parts to stick correctly, you may need to adjust height of first layer perfectly and to reduce "Elephant foot compensation" from default value 0.2mm... to 0.1mm. Modified settings: PrusaSlicer > Print Settings > 0.20 QUALITY MK3 > Advanced > Slicing...Isopropanol 99.9% / Isopropyl Alcohol / IPAManufacturer Part Number: 1000-ISO-TRIGGERChild Proof CapNatural Trigger spray cap for bottles with a 28mm neck (OFF, Spray, Stream)1 LitreKleenex • Ultra Soft Pocket TissuesFor preparing-cleaning heated printer bed.PRINTING SETTINGSPrinting Settings for MCPP BasicFil or AmazonBasics PETG Filament on PrusaSlicer...for Spring Steel Sheet with Smooth Double-sided PEIFor BIG parts to stick on TEXTURED PEI Powder-coated Spring Steel Sheet sheet, I increased recommended bed temperature from 60-80°C (for AmazonBasic and MCPP BasicFill PETG filaments) to 85°C (First layer) and 90°C (Other layers). I printed BIG parts in my own Temperature Controlled Enclosure. Temperature inside enclosure was 35°C. E3D V6 HotEnd is rated to 40°C ambient operating temperature. As you approach that temperature, cooling efficiency is reduced, allowing more heat up past the heatbreak. This can cause low temperature filament to soften in the mechanism to cause feed problems.Prusa3D • PrusaSlicer Modified settings: PrusaSlicer > Filament Settings > Prusament PETG > Filament• "Extruder: 240°C".• "Bed: 85°C / 90°C". Modified settings: PrusaSlicer > Print Settings > 0.20 QUALITY MK3 > Layers and perimeters• "Ensure vertical shell thickness: disabled" - I had problems with thin 45° hanging angles when it was enabled.• "Perimeters: 3" - infill pattern is less visible on surface.• Seam position: Rear - I printed most of the parts with "Rear" setting selected. It created line at the back of the parts, but front and side surfaces were perfectly smooth. Modified settings: PrusaSlicer > Print Settings > 0.20 QUALITY MK3 > Inflill• "Fill density: 80%". Modified settings: PrusaSlicer > Print Settings > 0.20 QUALITY MK3 > Speed• Reduced printing speeds (10-20-180-400). Slower speeds results in smoother and glossier surfaces without matte areas, reduces printing noise with vibrations... lesser probability for corners of big parts to unstick from heated bed, because of shrinking.• "Travel: 180" - low speeds (like 20) creates surface blobs after long travel distances.• "First layer speed: 10" - for better adhesion. Modified settings: PrusaSlicer > Printer Settings > Original Prusa i3 MK3S > Custom G-code• I added few lines to G-code to remove filament blob on nozzle right before printing starts and raised intro line to reduce wearing of steel sheet plate surface.G0 Z50 ; ADDED LINE - NOZZLE BLOB - Z up 50 mm to clean filament blob from nozzle before printing.G4 S5 ; ADDED LINE - NOZZLE BLOB - Pause 5 seconds to clean the nozzle.G0 Z-50 ; ADDED LINE - NOZZLE BLOB - Z down 50 mm to initial position.G0 Z0.5 ; ADDED LINE - INTRO LINE - Z up 0.5 mm for less intro line adhesion to prevent steel sheet plate surface from wearing.G0 Y-1 ; ADDED LINE - INTRO LINE - Y shift 2 mm intro line default start position to prevent steel sheet plate surface from wearing.STL FILESFor better quality and safety... I printed majority of parts separately.To split group and to remove some parts:1. Open “*.STL” file in PrusaSlicer Edition.2. Click on [ Split to objects ] button.3. Select parts one by one, which you don't want to print.4. Press [ Del ] key on keyboard.You can edit STL files with free and open source 3D creation suite Blender.Import “*.STL” file:1. Blender 2.8 > File > Import > Stl (.stl).If imported STL object is not visible:1. Select imported object in “Scene Collection” list (top-right panel).2. In “Object Mode“ (top-left drop-down) > Object > Set Origin > Geometry to Origin.Small_Box.STLSmall Box Bottom for Velcro - Fill and Bridging angle: 45°Small Box Bottom for Attachments (5) - Fill and Bridging angle: 45°Small Box Enclosure (5) - Fill angle: 0°Small Box Holder for IKEA OLOV adustable legSmall_Box_Parts.STLSmall Box Back Plate with 8mm x 2 HolesSmall Box Back Plate with 6mm x 2 HolesSmall Box Back Plate with 8mm x 3 Holes (4)Small Box Back Plate with 6mm x 3 HolesSmall Box Back Plate with 8mm x 4 Holes (1)Small Box Back Plate with 6mm x 4 HolesSoldering Helper (1)Knobs.STLKnurled shaft has 18 teeth, so you can mount knurled knob in 20° angle fixed positions only. If you want to align knob to various angles, you can use different knob inserts.Knob Cover with Triangle Pointer (3) - Seam position: RandomKnob Cover with Circle Pointer (2) - Seam position: RandomTriangle Pointer Insert (3)Circle Pointer Insert (2)Pointer Insert Helper Height 0.4mm (1)Line 1: 15mm Shaft Adapters (-4mm plate)Line 2: 15mm Shaft Adapters (-2mm plate) - For Bourns PTD902 Potentiometer ► Insert 3 (2)Line 3: 20mm Shaft Adapters (-4mm plate) - For Alpha SR2511F Switch ► Insert 1 (3)Round shaftKnurled shaft 0° - Knob arrow aligned with teeth spikes (0°).Knurled shaft ±10° - Knob arrow aligned between teeth spikes (to rotate knob ±10°)Knurled Shaft +5°, -5° - Knob arrow aligned 5° after or before teeth spikes (to rotate knob ±15° or ±5°).Connectors_and_Spacers.STL35° Angle Connector (1)Connector for Small Box Plates (1)Spacer from 9mm to 7mm Hole (2) - For Bourns PTD902 PotentiometerSpacer from 11mm to 7mm HoleSpacer from 11mm to 8mm HoleSmall_Box_Plate_1.STLSmall Box Plate for 1 Box (1)Small Box Plate with Extended Front for 1 BoxSmall_Box_Plate_2.STLSmall Box Plate for 2 BoxesSmall_Box_Plate_3.STLSmall Box Plate for 3 BoxesSmall_Box_Plate_4.STLSmall Box Plate for 4 Boxes (1)Angle_Adapter_1.STLSingle box angle adapter doesn't work well, if pad is not connected to other boxes with connector. Back is not heavy enough to maintain stability, when pushing on the knob under angle.35° Angle Adapter for 1 Box (1)Angle_Adapter_2.STL35°Angle Adapter for 2 BoxesAngle_Adapter_3.STL35° Angle Adapter for 3 BoxesAngle_Adapter_4.STL35° Angle Adapter for 4 Boxes (1)