Micro speaker having a hermetically sealed acoustic chamber with increased volume

A method of manufacturing a micro speaker assembly comprising:

• forming a micro speaker enclosure having an enclosure wall separating a surrounding environment from an encased space, wherein the enclosure wall defines, in part, an acoustic channel that acoustically couples the encased space to the surrounding environment, and the enclosure wall comprises a chemically etched insert molded metal portion that is mechanically interlocked and hermetically sealed to a plastic portion, the chemically etched insert molded metal portion having an interlocking end comprising a planar side that is planar to the metal portion and an out-of-plane side that is outside of the plane of the metal portion and at a right angle to the planar side, and the planar side and the out-of-plane side are entirely embedded within the plastic portion;
• and positioning a speaker assembly within the encased space, the speaker assembly having a sound radiating surface facing the chemically etched insert molded metal portion of the enclosure wall, a voice coil extending from the sound radiating surface, a magnet assembly having a magnetic gap aligned with the voice coil, and an acoustic chamber formed, in part, by the chemically etched insert molded metal portion of the enclosure wall and the sound radiating surface.