3D printing a large horn - ES-290 by Joseph Crowe

Best of luck with assembling and finishing those horns! 👍
I printed the ES-450 and ES-600 on a Bambulabs X1C in PLA. My settings:
0.4mm nozzle, 0.24mm layer hight.
5% gyroid infill
2 wall loops (should've used 4, but 2 worked kinda). Only 2 wall loops leaves small holes/gaps in the print, which impedes internal coating.
To increase stability of each printed part and reduce the risk of resonances I "filled" the horn with casting resin (not 100% fill, only so much as the gryroid infill and all walls are coated with the resin). Makes the horn quite inert.
The later sanding and filling took ages though, and the horns are still miles away from the beauty of Crowe's CNC machined wood products. But cheaper, eh?
What was your process for coating the gyroid infill with the casting resin? I'm printing an ES-600 and considering filling the horn with resin, will probably use bondo spot putty and filler paint for the outside of the horn.
 
bpark99, I drilled big enough holes in the 3d printed parts (not with a normal drill bit - that ripped the layers apart; I used a conically shaped step-drill-without-steps). Then I filled in some casting resin and closed the hole with masking tape. Then I moved around the part every half hour or so until I knew the resin would harden (left some resin in the mixing cup). Not rocket science.
These days I'm not sure if all that is really needed. Print wil six wall layers - that should be plenty stable and resonance free.
 
Great project! I also have experience with 3D printing a horn. My thought about your horn is this: a lot of printing has nothing to do with the horn contour itself. To save on countless hours of printing and filament, wouldn't it be a good idea to print just the horn contours (that what counts soundwise) and use cheaper materials like concrete to make it a solid object that you can mount on top of a box?