Teardown Process
The JBL Speaker looks very seamlessly integrated from outside with zero screws. So I used a file and a hammer to pry the curved perforated metal front off to examine further.
I broke off the soft silicon pads on the bottom of the speaker and smashed open one end.
I tried to pry off buttons from the other end to reveal inner structures, then used it as a breaking point to pry open the exterior shell. The exterior shells turned out to have three layers and screwed to the black inner part in an invisible way (screws were hidden behind the two round pads at the ends).
Breaking down the innermost part was very painstaking. I first unscrewed all the screws I could find only to realize the halves of this chunk seems tightly glued along the middle line. I tried to pry it open from multiple angles with no luck. Inspired from the teardown videos of other JBL speakers, I managed to find a hidden screw located at the central back and via here was finally able to break it open.
Here’s what’s at the heart of the JBL Speaker: a tube, some damping foams, two speaker drivers, one main circuit board, and one lithium battery underneath.
Here’s the final look from the JBL teardown with labeling.
Two Interesting Designs
- Bass Reflex Tube
- How it works: when the speaker is on, the speaker drivers push air through the tube to the outside. The shape of the tube is also carefully designed to resonate in a way that boosts lower frequencies and improves bass response.
- Three-Layer Outer Shell
- The three layers tightly bind with one another and add extra colors & textures to the speaker’s exteriors. They also provide stronger binding for the relatively delicate inner part and protect it from potential impacts. I also think their particular shape acts as a weight balance for the speaker to stay flat on the table with the perforated steel front always facing forward.
Tools & Techniques during Teardown
| Tools | Techniques |
| Pliers of different sizes | Screwing/Unscrewing |
| Cutting plier | Prying |
| Files of different sizes | Smashing (attempted) |
| Philips screwdriver |
Component & Material & Manufacturing
| Component | Material | Manufacturing Technique |
| Perforated Steel Front | Perforated Steel | Sheet Metal Punching, Stamping |
| Outer Shell (Three-layered) | Plastic (ABS/Polycarbonate) | Injection Molding |
| Round End Caps | Plastic (ABS or Polycarbonate) with Rubber Inserts | Injection Molding, Overmolding |
| Speaker Drivers | Diaphragm: Mylar/Polypropylene, Frame: Metal (Steel/Aluminum) | Stamping, Thermoforming |
| Passive Radiator | Rubber, Metal Disc | Rubber Molding, Stamping |
| Bass Reflex Tube | Plastic (Polycarbonate or ABS) | Injection Molding |
| Main Circuit Board | Fiberglass (FR4), Copper Traces | PCB Manufacturing, Surface Mount Technology (SMT) |
| Battery | Lithium-ion, Plastic casing | Cell Manufacturing, Ultrasonic Welding |
| Wires and Connectors | Copper, Plastic Insulation (PVC) | Wire Extrusion, Connector Assembly |
| Acoustic Foam/Damping Materials | Foam (Polyurethane or Polyethylene) | Foam Extrusion or Molding |
| Buttons and Control Interface | Rubber (Silicone), Plastic (ABS) | Compression Molding, Injection Molding |