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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 25th April 2019, 01:23 PM   #1
Spike415 is offline Spike415  United Kingdom
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Default Polymate3D FD61 - 3D Printed Full Range Speaker Driver- In development

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Hello everyone

Facebook Page -> Polymate3D - Product/Service - London, United Kingdom - 50 Photos | Facebook

Over the past 2+ years, I have been designing speaker driver prototypes using my own built 3D printer. Printed Cabinets I have already done, as has everyone else, but no one has attempted to create a full range speaker driver that actually attempts to compete with drivers you can buy off the shelf. FD61 is being developed to change this!

Not only this, but I found it very frustrating when developing speakers to know how a speaker material will effect the sound short of developing lots and lots of speakers. With this in mind, FD61 is being developed to have a interchangeable drive train as well.

Except a steel tube, copper piece, wire, screws and glue, every single component off the design is 3D printed. These include:

Cone
Former (Bobbin)
Surround
Spider


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Click the image to open in full size.

Over 20 prototypes have come and gone, and development is almost at a stage where I will be offering these out in a kit form to be assembled at home like a airfix kit. I have decided now is the time to create a thread and share some images and my facebook page that has been created around this. I am trying to get a feel of the scope this has, and what people would like to see...and what they would not.

To give you an idea of where I am at, here are some details:

60mm driver
76dB @ 1W
Qts of 1.2 (This is continuing to drop. Attempting to get below 1)
Mms of 4g


I have built multiple different speaker cabinets before in the past, and a avid fan of full range drivers. Especially my Mark Audio Alpair 7's, but Fountek, Dayton, Hivi, Peerless, and Visaton are all brands I have worked with and developed around.

I have a WT3 analyser and a flat response microphone which I have used in the past as well to get results from the finished models to get an idea of what is working and what is not.

If you got this far, thank you very much for your time as interest. I will keep an eye on this thread, but will routinely be putting updates on my page. Any questions and queries are more than welcome.

Paul
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Old 25th April 2019, 11:52 PM   #2
Spike415 is offline Spike415  United Kingdom
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Just an update to my original post. Back at home so can get the exact results as analyzed from the WT3 for Prototype 24:

Re: 4.018
Fs: 83.44Hz
Qts: 1.102
Qes: 1.941
Qms: 2.551
Le: 0.412mH (Copper shorting ring coming)
Mms: 3.903g
Vas: 1.046L
SPL: 76.85dB @ 1W/1m

Also, here is a link to a short video showing excursion movement at this stage. The plan is to release as a kit on kickstarter once other issues and finished quality of parts like the surround are improved. Target pricing for a single driver in kit form is £35.

Polymate3D - 3D Printed Speaker Excursion Test - FD61 P24 | Facebook
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Old 28th April 2019, 06:04 PM   #3
lifting is offline lifting  Israel
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What material are you printing with ?
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Old 28th April 2019, 06:36 PM   #4
pinkmouse is offline pinkmouse  Europe
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Polymate3D FD61 - 3D Printed Full Range Speaker Driver- In development
Cool project, I shall be watching!
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Old 28th April 2019, 07:48 PM   #5
Spike415 is offline Spike415  United Kingdom
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Hey lifting

Thanks for the message. I am using a mixture of materials and printing thicknesses depending on the part. This is both layer height and nozzle diameters.

The Cone is printed in a carbon fibre composite with a density of 1.37g/cm2. This has a high tensile modulus which helps with high frequency response. Another material I like the sound off is a wood like filament which has a much lower density of 0.9g/cm2. This helps improve SPL. Interesting tidbit - The speaker cone when printed consists of over 160 layers. Here is a picture of the wood like material in a earlier prototype:

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The Former that the voice coil has been glued to has been an interesting part due to the distinct difference in sound depending on the material. For lower power testing I have used the wood like filament, but for higher power testing I use polycarbonate. This is due to a softening temperature of 120c which gives me enough scope for this form of driver.

Surround and spider are printed in a 85A Shore hardness flexible filament. Attempting to get the level of compliance I have wanted has proved tricky.

The basket and part that holds the magnets is currently being printed in PLA due to its rigidness and ease of printing, as are my speaker cabinet designs. I end driver will move to PETG to get away from the troublesome low melting temperature that PLA has.

@ Pinkmouse

Thanks for your interest. If you have facebook your welcome to like it and get any updates on there. I plan to update here anyway though if not.

Any other details anyone wants, or doubts/concerns on the design or development just let me know. I want to make it not only a 3D printed full range driver. I want to make it compete and open a new world of driver interchangeability and customization. Actual print finish on certain parts are planed to be improved as well.
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Old 28th April 2019, 08:03 PM   #6
pinkmouse is offline pinkmouse  Europe
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Polymate3D FD61 - 3D Printed Full Range Speaker Driver- In development
You could try the Filaprint PLA+ rather than PetG. Prints really well, and I'm very impressed with the dimensional and temperature stability and strength once annealed. The semi-matt finish looks nice as well.
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Old 28th April 2019, 08:58 PM   #7
Spike415 is offline Spike415  United Kingdom
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I have definitely had a good look at annealing HTPLA to improve the heat issue, but the Polycarbonate is currently good to 120c, and the driver is coping perfectly fine up to distortion on a TA2020 amplifier which is beyond what the driver needs to cope with. The wood like material however would be limited to around 6W. Okay for this driver, but its too easy to be damaged.

In the case of later on producing a bigger driver which need more power handling, I have materials lined up to cope up to around 190c.

Now matt finish is another story. Im not a fan of glossy finishes, so its definitely something I will consider. HIPS is also a great material for matt finishes if you can deal with the warping and potential layer cracks. Heated chamber is the way to go with that kind of thing.

The plan is a kit for the driver, but cabinets are open to be purchased or built yourself. Would making the cabinet on your 3D printer appeal, or would you go traditional with wood?

Paul
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Old 29th April 2019, 06:46 PM   #8
pinkmouse is offline pinkmouse  Europe
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Polymate3D FD61 - 3D Printed Full Range Speaker Driver- In development
Well, I'm in the middle of a 100Hr+ print time nautilus style enclosure ATM...
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Old 29th April 2019, 09:11 PM   #9
Spike415 is offline Spike415  United Kingdom
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Hope it goes well. Have you considered increasing the nozzle diameter to improve speed? Hope it goes well. I am working on the magnet motor again at the moment. Checking for performance and inductance.

Paul
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Old 16th May 2019, 08:54 AM   #10
Spike415 is offline Spike415  United Kingdom
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Been a while but P25 is underway.

I have been extensively reassessing each component in the aim to improve SPL, lower inductance, and extend the frequency range. P24 started to roll off early at 4Khz like a midrange driver, with -10dB @ 8Khz. Due to this I have been designing multiple speaker cone designs, then moving on some to production. These cone profiles have then been tried on 4 different materials, including 2 which push the limits of how high I can go in respect to Young's modulus (Stiffness) of the material.

I have also been working on different methods to improve the print quality of different components in different materials. Please see below the latest cone profile, former and surround, along with it next to P24 to show print quality differences.

Paul

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