PyBadge LC Speaker 

We designed three different cases for the back of the PyBadge to fit the PyBadge header version and the PyBadge LC model, which has no headers or connectors. The third version of the case includes cutouts to connect Feather Wings. 

Having no headers keeps the case design slim, so we’ll need to solder our speaker to the solder pads on the back.

Start by measuring the wire length. I looped it around the speaker to ensure we have enough wire to solder.  Next we'll remove the pico connector and align and solder the wires to the pads.

Attach Speaker

Remove the protective backing on the front of the speaker (fabric side) and stick it over the outline on the PCB.

We can use mounting tack to secure the lipo battery.

Attach Battery

Roll up a small amount of tack and place over the "battery" text on the back of the board. We used the 350mAh lipo battery. First gently curve the wires to make it easily when plugging in the connectors.

Lay the battery over the tack and gently press the battery to adhere it to the tack.

Case Assembly 

Now we can move on to assembling the top half of the case.

We’ll use superglue to attach the button housing. This medium grade starbond superglue dries slowly so you can align the pieces more carefully.

To avoid hazing on the case, a small desktop fan will help keep the fumes away. You can use clamps to hold parts together as they dry.

The display bezel is attached after the button housings have fully cured.

Gamepad and Buttons

We can print our buttons in PLA or even flexible materials. 

Install the gamepad by inserting it into the housing. Add the washer and use an M2x5mm long screw to secure it in place.

We’ll also setup the action buttons with a washer and machine screws. This prevents the buttons from coming out.

Reset Button

An extra button is added to the bottom half of the case for better access to the RESET button. Pass the smaller diameter end through the cutout on the case until the larger end lays flat around the cutout. 

Mount PyBadge

Place the PyBadge board over the standoffs and line up the mounting  holes. Insert with the USB port first, at an angle. 

Then fit the top half over the PyBadge.

Now you can insert four M3x6mm screws to secure the both sides of the case.