3D printed waveguides

[augerpro]

Check on the mounting holes (I'd forgot!) and check on the 2nd support for PS. Also realized the radius I have for the PS is too large, should be .75" radius or 1.5" diameter.

[augerpro]

Gotta get some measurements of the screws I'll be using to finalize the bolt hole size, but here is the finished product.

[augerpro]

On the final designs I'd like to include these ribs which can than be filled with epoxy, fiberglass resin, etc, for further strength and dampening.

[Face]

No flange for the driver? TNA, received your message, expect a reply in the next day or two. Thanks!

[augerpro]

No flange for the driver? Thanks!

I turned it off in that last pic for clarity. It's just hidden in the others.

[badman]

The ribs are a great inclusion- though I'd suggest they'd be more valuable with cross members (making more of a "grid" structure) which would require minimal material

[augerpro]

The ribs are a great inclusion- though I'd suggest they'd be more valuable with cross members (making more of a "grid" structure) which would require minimal material

Done. Took me awhile to figure out how to do this elegantly.

like recessed screw holes or something,

Done.

[augerpro]

I thought the elliptic profile might have me beat, but the helpful Fusion 360 community helped me conquer it!!!

[300Z]

I like that, it looks quite nice.

[augerpro]

So in an unfortunate turn of events, Dan will not be able to supply printed samples. TNA will help by CNC milling them in wood, and the phase shields are cheap to have printed by the retail outfits (and easy to attach to wood) so design and measurements will move forward. But if anyone has access to industrial machine and can help out let me know, I really think the 3D print version will be the most accessible in the future.

[augerpro]

Little bit of progress, Bill has printed one of the waveguides: http://www.htguide.com/forum/showthr...l=1#post620625

Will check fitment and quality and go from there!

[TN Allen]

It's great that someone, Bill in the link above, has printed a guide and provided a practical example of what can be expected for time and finish.

In the linked exchange molding guides is mentioned. Injection molds are expensive, and although the cost per part is low for long runs, the initial mold and setup probably would make the cost per guide in this case quite high.

Some of the following is repetition of earlier posts to this thread, but seem worth repeating as someone new to the discussion may want to offer new ideas about the following.

An alternative is to produce a splash mold, which is just the male form over which the guide can be produced using resin and cloth. Given the back of the guide is likely to be inside an enclosure, its appearance wouldn't be a problem, in other words, as long as the molded surface is good, the back can be a mess. With the male/splash mold, a person could go to a boatbuilder/glass shop and have a few guides molded in whatever color is wanted and available. Otherwise, guides could be molded more crudely at home using resin and cloth, provided a release agent is used, or possibly something as simple and inexpensive as spayed foam.

The time and material for milled guides is less costly than printed guides given the cost/hour and time for printing, and as various people have indicated allows guides to be milled or turned in solid wood baffles, which can be very attractive. The key is to find someone who will mill these inexpensively. I think early on in this thread I mentioned that the least expensive way to produce round guides is to turn them using a jig to swing a cuter through a radius on a lathe. There's also the possibility of building a router jig to produce round guides, and this could probably be modified to mill oval guides. The router jig option is best for guides in a baffle, eliminating the problem of turning an unbalanced piece of wood on the lathe.

[Dirk]

A little late to the party, but count me in as another person with a 3D printer and a desire to make some waveguides. I'm only on page 2 of the thread, but working my way through it.

Being a home gamer, my guides are going to have to max out at about 7" in diameter, but I don't think that'll be a huge hindrance. I think it'll be enough for the OC19 and a conservative crossover.

[critofur]

I've posted threads with subjective impressions before, and unless your initials are JB, they don't find much favor here. But I'm certainly open to it.

Your metal vs softy shootout was one of my all time favorite projects and I for one was disappointed when you seemed to take a few year long hiatus from posting - you, Mark K, J Kim, and Zaph are among my favorite posters - all the best seem to get discouraged or otherwise unable to continue participating for one reason or another. I do also value J.B.s contributions of course...

[augerpro]

Your metal vs softy shootout was one of my all time favorite projects and I for one was disappointed when you seemed to take a few year long hiatus from posting - you, Mark K, J Kim, and Zaph are among my favorite posters - all the best seem to get discouraged or otherwise unable to continue participating for one reason or another. I do also value J.B.s contributions of course...

Sentiment like that means a lot to me! Thanks. Funny thing is I live in an apartment now and don't have the ability to actually do any woodwork, But I have the most projects ever in progress because I've been able to partner with people who don't mind doing the heavy lifting. I'm grateful to have the support to realize some of my ideas because others want to help!

And I like that I can add to the community by taking up topics of interest and bring real data to the discussion. Among all my ideas and designs that are forthcoming, I believe it will actually be these waveguides that have the biggest impact/usage for other builders.