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Carpentry is the big $$$ problem with horns. Have we reached the point where a bass horn can be inexpensively reproduced in a 3D printer?
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I drew up a few horns in Sketchup a while back intending to print them in sections on a 3D printer. The largest (reasonably priced) "home" printer late last year had a capacity of 12" x 12", so up to 300 Hz horns seemed reasonable in four petals plus throat.
For bass horns, I think a flat-pack could be designed and cut with a CNC router. You may have seen organizations using this method to deliver ready-to-assemble small houses to impoverished populations in poor countries. They literally fit together like a puzzle.
Personally, I chose to make a mold with a CNC router and plasticine clay and plastered eight pieces that fit together. After trial and error factored in, it turned out to be a few year long project for a pair of 100 Hz hypex horns (full space).
A printer large enough to do a bass horn goes for about $40,000. Building from wood is considerably more cost effective.
A Sawmill probably costs more yet we use lumber.. seriously, you would have to go to a commercial service, which at some time will dexist
I have a horn that is a prototype. I called around last year asking those with 3d printers what it would cost. They all said the horn was too big. I figured I'd wait another couple years and then call around again.
High sensitivity, wide dynamic range, low distortion, and smooth frequency response. Pwk
and you are only going to use for very high frequencies.
How big do you think these things are?
I was thinking of all the twists and turns that a cabinet maker must build to make a labrinth behind a full sized speaker
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