Acoustic Horn Design – The Easy Way (Ath4)

I've mounted woofers near floor and close to carpet, distance 1,5 meter and in the middle of a room:
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below is 60x200cm electrostatic speaker so open baffle and along longer wall 2 meters apart, visible on the right side of above picture.

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This is the manufacturing process I'm thinking about -

1) 3D-print ribs with grooves as the petal joints,
2) glue petals made of perforated cardboard into the ribs - this should create the overall shape of the horn,
3) cover the front side with petals cut of thin sheet metal (glue them to the ribs),
4) coat the back side with something that will glue together the (perforated) cardboard and the metal sheets.

Should this not be enough damped, another layer of metal sheets could be put at the back side.
Perhaps the cardboard could be replaced by (perforated) sheet metal right away.

The aim is to have a light and well-damped structure.

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There were some indications that the segmented shape could be very smooth indeed: https://www.diyaudio.com/community/...-design-the-easy-way-ath4.338806/post-7331853

Increasing the number of segments, i.e. approaching round shape, lead to a slightly worse response, from which I gather it helps to further break the axial symmetry this way. At the same time the radiation pattern is virtually the same as of round. That's all I know for now. It may not be a significant difference but certainly noticeable in the data.
 
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