Acoustic Horn Design – The Easy Way (Ath4)

what were your thoughts on how to achieve stiffness of the baffle?
I haven't had such thoughts 🙂
I think it's already good enough, actually. The baffle is pretty thick and can be printed really stiff, if desired. It's just a toy, this is not rocket science. Anyway, I'd be perfectly happy even with the (mostly hollow) PLA prototype.
 
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Still some minor modifications...

xs-enc339.JPG
 
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The overall thickness is 44 mm, which is really what makes it stiff. It's like holding a piece of wood, only much lighter. This is nothing like an injection molding, if that's what you mean by a "thin and resonant baffle made from plastic". Did you ever try to actually print anything?

Every loudspeaker is a toy, isn't it.
 
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I've been playing with a 5 inch wavguide idea.
but crossover will be around 2.1-2.5kHz or so.
keep in mind that (in particular with this WG size+ crossover frequency combination) it's essential to consider the whole baffle (speaker) to be part of the waveguide.
a 5" driver will just start being directional at around 2 kHz, of course depending on the baffle shape.

I guess you can find lots of good waveguide examples for dome tweeters at www.somasonus.net

I can show my very rudimentary "hand carved" version:

WG.jpg

the faceted "roundovers" are mostly for visual pleasure, but they optimize the directivity. roundovers would probably be even better.

EDIT: and never mind if you were asking for a CD waveguide!
 
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You can always try to scale down the Tritonia XS even further (and make it a bit more open), but frankly I don't see the point. The smaller you make it, the more attention you will need to pay to the enclosure (edge roundings, etc.). The current XS has 120° nominal beamwidth, which seems just fine to me for that kind of design. It's not so easy to make it wider than that.
 
I’ve been fighting my printer lately. Sometimes it feels like more of a hassle than a convenience…
Do you think your horn flare would be beneficial for a midrange horn? I was going to try and build one with a b&c 8pe21 that would be crossed at 150. I was also thinking of trying to create a phase plug that resembles your spherical wavefront guide. Your opinion is appreciated.
 
Do you think your horn flare would be beneficial for a midrange horn? I was going to try and build one with a b&c 8pe21 that would be crossed at 150.
The basic understanding of horns always applies: a horn/waveguide going that low will be either inefficient or very big. Hence, "beneficial" is likely to require a large device. In which case, yes, it would be beneficial.