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Polymate3D FD61 - 3D Printed Full Range Speaker Driver- In development
Polymate3D FD61 - 3D Printed Full Range Speaker Driver- In development
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Old 17th May 2019, 12:10 PM   #11
TimbreAudio is offline TimbreAudio  United Kingdom
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Have you looked at the BMR drivers, I wonder if a flat cone 'honeycomb' could be a good concept to develop. I saw in Fusion 360 you can easily model, modal nodes.
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Old 17th May 2019, 12:34 PM   #12
Spike415 is offline Spike415  United Kingdom
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Hello TimbreAudio

It is something I have looked at for sure but I find the results harder to predict the result. Was debating maybe a flat surface with a spiraled support on the back to vary to distance. For now I will stick to the cone design, but I will certainly come back to BMR!

This next cone design if things go well should extend to 10khz. Possibly further. Hopefully will get this done this weekend. Results will be posted as soon as I have them.

Paul
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Old 20th May 2019, 02:02 PM   #13
TimbreAudio is offline TimbreAudio  United Kingdom
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Now if only that can 3D print Graphene. It will be next centuries wonder material. I see new transducer designs where the entire thing is graphene. As it’s conductive even the coils could be specially printed. Come on future.

Good luck with the next print!
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Old 27th May 2019, 12:37 PM   #14
Spike415 is offline Spike415  United Kingdom
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Default P25 Results & 6 Way Shootout

Hello everyone

Big update post for you all. P25 is now up and running using a diamond dust PLA composite cone and former. SPL and Q values were worse, but this was expected due to using the same magnet motor but with a taller winding, resulting in a slightly lower inductance. results you see below are done on a Blue Snowball microphone so please use this only for comparison between one another. I attempted to use my old EMM-6 but the results were not right at all, reading nothing beyond 8khz.

Click the image to open in full size.
Front view of the latest P25 prototype

Click the image to open in full size.
Side view of P25 showing its mild steel galvanized pipe and the light permeating through the cone material. Possible back lit cone anyone?

So next up is the frequency response of P25, along with the results of P24 and 4 other drivers. The aim for P25 was to improve high frequency response.

Click the image to open in full size.

Drivers:

FD61 - P25 = Diamond PLA composite prototype
FD61 - P24 = Carbon Fibre composite prototype
Dayton PS95 = My reference driver. Great full range driver
Tectonic BMR65 = Nice full range BMR
Bose Driver = Sounddock 2.55" drivers
Samsung HTK = Cheapo driver used in designs such as the J4550

So the plan was to have 2 of my own, 2 good well known drivers, and 2 OEM drivers so I can see where my driver fits in at this stage, and see what needs to be my next focus. Results were done at as close to the same volume as possible with the distance between driver and microphone being the same.

Click the image to open in full size.

Click on to see in more detail

P25 = Dark Blue
P24 = Grey
PS95 = Dark Green
BMR65 = Light Green
Samsung = Orange
Bose = Light Blue

So what am I taking away from this?

1) P25 is definitely an improvement from P24 in high frequency extension

2) OEM drivers Lack in the lower end and fall between my high end frequency performance and better brands

3) There is still work to do on the magnet motor to lower the bass bump P24 and P25 both have, although P25 has also improved in this respect

4) Overall the driver is very capable when you consider the companies I am comparing it too.

So whats on the plans for P26?

First step will be fitting and testing P25 again with a different motor arrangement and with a dust cap fitted. Then extra tweaks to the cone profile to help improve rigidity further. The surround will be attempted with a thinner wall to improve compliance and lower Q, and the magnet motor is having a copper piece centrally fitted along with a larger steel tube to improve the magnetic gap strength.

Click the image to open in full size.

Steel tubes. The left was used in earlier prototypes. The middle one is the current one for P24 and P25. The right are new tubes just come in. 3.2mm thick walls compared to previous 2.0mm.

As always any questions, feedback, input and criticisms are welcome. Hope you have enjoyed the update, and I will hopefully be back in a couple of weeks with P26
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Old 3rd June 2019, 01:24 PM   #15
Spike415 is offline Spike415  United Kingdom
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Small update in relation to the magnet motor improvements.

I fitted the new thicker tube and run tests against the thinner version and results came out almost identical. I increased the winding length using a thicker wire and results came out almost identical again, meaning that saturation is not the issue in improving performance.

Up until this point, I have run a very large magnetic gap and tried to compensate for this, but my next step will have to be to reduce this gap. This should be too much of a issue as my alignment system works fairly well already, and there are improvements to this as well.

The next stage is solely going to be improving my magnet motor whilst maintaining or reducing moving mass.

Stay tuned to see what comes next!

Paul
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Old 22nd July 2019, 02:26 PM   #16
Spike415 is offline Spike415  United Kingdom
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Hello. 6 weeks and a LOT has happened in my personal life, but also to FD61. If you not interested in the details and want to see it in action, here is a link

YouTube

The larger steel tube did not help improve performance, but did allow extra space in the magnetic gap. With this in mind, I created a new frame which would improve my cone/former alignment further, ignored the cone profile, and got to work on improving the magnet motor power.

After a few iterations I have now got to this stage:

Click the image to open in full size.

This new design has allowed me to reduce the magnetic gap width which has helped improve power output. This design also extends out through the center, making this a phase plug based design. This change also reduces the former length reducing mass. This version was 3.75g, and there is potential to reduce this.

Next step was to hook it up to the WT3 analyser and check the results:
Click the image to open in full size.

With a SPL of 78.7dB @ 1W, this is the most powerful model so far. I am using the Aura NS3 as my benchmark in respect to SPL, as I feel this means I am matching a driver built by a manufacturer which is intended to the full range area, and not the 76dB Tang Band have on a very heavy 3" subwoofer design.

To finish off the youtube video and sound is off an older smartphone, so take it with a grain of salt, but hopefully it will give an insight to where the driver is at.

As always, all and any questions / concerns are welcome. Hope you have enjoyed the update

Paul
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Old 28th July 2019, 11:11 PM   #17
Spike415 is offline Spike415  United Kingdom
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80dB is finally within reach!!!

Just a quick update as this driver sets and gets some hours under its belt. Done analysis with my WT3 analyser and we have achieved 80dB in the magnet motor test driver. Alignment method is working very well with a hot swap of the magnet motor working perfectly. Inductance is high but there are some ideas around that.

Click the image to open in full size.

Hope this update is a nice insight. If you are reading these and have any questions please don't hesitate to ask. Im open to all and any questions or general discussion.

Paul
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Old 29th July 2019, 01:21 PM   #18
3eepoint is offline 3eepoint
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Hi Paul,


your work is verry interesting, but I wonder if you use simulation software to evaluate your results. Tools like femm4.2 would help you optimize your magnet structure a lot.


Impressive Work annyways =)
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Old 29th July 2019, 04:57 PM   #19
Spike415 is offline Spike415  United Kingdom
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Hello 3eepoint

Thank you very much . I do use FEMM 4.2 and recently adjusted the settings to a axisymmetric layout rather than planar. This is helping a lot, but there is differences in the magnets I am using and the ones FEMM has set out as standard. I have also been lucky enough to have access to play around with FINECONE in the past which helps my understanding of cone profiles and material effects before I actually try to implement them.

I will keep updating as improvements happen. The plan is still to make it available to buy in a kit form. Likely around the 35 mark and make sure there are options for different material cone and profiles. I would like to effectively make a learners ecosystem where you can experiment with the driver, the enclosure types and materials on a smaller scale. Then use what you learn to better effect with a bigger system.

Paul
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Old 30th July 2019, 02:22 PM   #20
ghemml is offline ghemml  Singapore
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Quote:
Originally Posted by Spike415 View Post

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SWEET....!!!!
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