In the cross-over between the era of tapes into that of MP3s, you’d see quite a few of those special cassette tapes that were actually digital music players inside. Some simply provided a 3.5 mm input, while others were complete MP3 players or Bluetooth receivers that just happened to also output to the magnetic read head of a cassette player. Recently [Jonathan Rowny] decided to make his own version of the latter.
Although getting the actual audio signal into the read head is easy enough – requiring little more than its equivalent being used as a write head on the cassette side – actually interfacing with the player’s mechanisms like auto-stop, reverse and so on requires the use of some gearing that detect motion on what would be the tape spools, as well as transfer the motion from the take-up spool to the other spool so that features like the auto-stop mechanism don’t get triggered.
A lot of inspiration here can be found in e.g. the videos made by [Clint] of [Lazy Game Reviews] who looked at a number of examples – including their internals – over the years, with various levels of functionality. For this particular implementation an ESP32-S3 module is used for the brains, along with a microSD card reader for music and a PCM5102 I2S audio codec to create the analog audio signal.
The gears were printed using an SLA printer and seem to work all right. Unfortunately he didn’t realize the importance of the capstan as the mechanism that actually transports the tape, so its motion was not measured as is done in the better cassette adapters. This will likely be corrected in a future iteration, however.