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Audio 3D printing Carbon fiber DIY Loudspeaker Speakers Technology

Exotic carbon fiber skinned loudspeakers with excellent stiffness – FR2

Additive manufacturing

Using additive manufacturing (AM) has many benefits over traditional construction methods, such as design freedom, fast product development and integration of functions into one part. There are drawbacks as well. The plastic AM parts tend to be low in mass and not very stiff. Air-tight walls are sometimes difficult to achieve, too.  Adding mass by increasing fill density of the print is not a good solution, since it adds build time and material cost. Stiffeners and bitumen paint were used in (Version 1). However, the stiffeners were cumbersome to paint with bitumen and it did not add significant weight. For Version 2, we used the vent as a part of the mechanical structure and used a thicker wall. But some additional means were needed to bring 3D printed enclosures on par with traditional cabinet materials.

Carbon fiber in loudspeker building

Dry carbon fiber tow was wound around the enclosure and then wetted with epoxy resin. The composite skin was sanded after curing and additional coats of epoxy were added. The result is a unique unidirectional carbon fiber surface finish. The composite shell adds mass and stiffness to the enclosure. The loudspeaker sits on four feet printed from TPU material, which allows rotating the speaker.

Make them yourself

The following changes were made to Thingiverse:

  • Updating the driver dimensions and screw pattern to the latest Alpair 7 MS.
  • The weight of the loudspeaker will try to bend the speaker stand. It was therefore changed from a shell-like structure to a solid.

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