Acoustic Horn Design – The Easy Way (Ath4)

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As for the injection molded waveguides, I would like to make it from clear (UV stable) plastic. Probably as a two-part product to keep the mold simple, with a separate aluminum mounting flange. Should not the transparent look be preferred, painted from the back side it could make a high-gloss quality finish with minimum effort.

I'm going to start a crowdfunding project soon, somewhere.
 
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I can still order the epoxy-coated sand prints, or make something of the CE series using this technology, but only locally (i.e. Czechia) as the shipping is quite a hassle - it's heavy and too brittle, I'm afraid. Too much work to pack it properly, not something I would be eager to do again.

If somebody living around here were willing to do it, I have no problem ordering these directly to him/her to ship it further.

Measured SPL data: #7402
 

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Probably it could be casted as two (thinner) aluminum pieces, put together as constrained layer damped (?).

This would be ideal, but probably quite expensive. Once I had the mold, casting with polyurethane cost only about $50/each. These had between 1" and 4" of wall thickness (1" at mouth, 4" at mounting,) and with the glass fill were extremely dead.
 
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I'm quite reluctant to buy an expensive mold to produce the waveguides manually by myself, that's something I don't feel like doing at the moment, honestly. So I just think about how to let it made in high enough quality so it wouldn't cost a fortune. There are really not many options I guess.

- Regarding vibrations and damping, I wonder how is the situation different when free standing (attached to a driver stand via the narrow end) compared to when mounted in a box, which can vibrate by itself in quite a complicated pattern. Is it supposed to be more critical or less critical when free standing?
 
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- Regarding vibrations and damping, ...
More on this, what's actually the biggest source of mechanical vibrations and resonances in waveguides? I would think the vibrations from a compression driver itself are miniscule, not something to worry about. So is it the bass driver, causing vibrations on the surrounding objects? Is it then possible to isolate a free standing waveguide by a damped (or completely separated) mounting? This would by my intuition. Or is it the sound itself? Wouldn't be aluminum alone satisfactory, if heavy enough?
 
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As to the actual level of the vibrations in a waveguide itself, I don't have a feeling for how critical it is, so I just made them dead as that can never be the wrong thing to do.

Free standing will have lower resonances than in a box. It's like a cantilever and those are always lower frequency resonances than a clamped beam. How much of a difference this makes is unknown. Even free standing, I would clamp the mouth to something and damp the mounts on both ends.
 
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It would be interesting to investigate how and how much does this contribute to the total sound radiation for different waveguide materials and their properties, when driven only by a sound wave at the throat. This would be a task for a FEM modeling I guess, which is out of my reach at the moment. My guess is that it would take an extremely flimsy device to have a substantial effect. Thin glass, maybe, I don't know - they do break with sound :)
 
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