Finally finished my Volumio box!
This was all designed in Fusion 360 and the enclosure is made from walnut, cut out on a desktop CNC machine.
The buttons are made from polyurethane resin, cast into an acetal mould that was also machined on the CNC machine.
The volume knob is a walnut and polyurethane resin combo, with the wooden part CNC machined and the top resin part cast in a silicone mould.
The custom PCB includes a proper power on / off circuit, actually cutting power to the pi safely after Volumio shuts down. The on-off button is the pushbutton on the volume knob rotary encoder.
I’ve been thinking about this project for a couple of years, but decided to dive into it a few months ago. No idea how many hours went into it, but I’d guess it’s at least 200, mostly late at night!
This project involved 3D CAD design, electronic design, custom PCB design, programming (just tweaking the GPIO Buttons plugin), CNC toolpath programming, silicone mould making, casting, laser cutting and 3D printing.
Super pleased with how it came out! Thanks for the awesome Volumio software and thanks to the friendly folks on the forum who helped me get to grips with troubleshooting the GPIO buttons plugin!