Concrete Filled Tang Band W3-1876S Subwoofer Enclosure

This is a remix of both HexiBase and zx82net printable subwoofer enclosure. It's designed to be printed in one piece and filled with concrete. This will save filament and improve rigidity. The port is located on the front and one side is flat so it can be used standing up.

With my settings this is a 48h print that uses 300m 1,75mm filament. Less than one kg.

It requires a 200x250mm print bed.

Once printed route some cables through the holes in the enclosure and secure it laying on a flat surface. Pour in concrete and vibrate. Smooth the surfaces once the concrete begins to set.

I´m printing this right now so more pictures will come in a few days.

Flip the model over on the other side before printing to make the integrated support work.

2019-09-27
The first print was a fail. It started to shift layers with 5% left to print. Probably because of the added weight to the Y-axis. I descided to do a test and fill the failed print with concrete anyway and that also was a fail. Tapping on the walls when it was filled with heavy concrete made it crack.

Leasons learned:
Reduce print speed and acceleration to avoid layer shift.
Sift the sand to remove any larger rocks.
Gently vibrate the mold, dont tap on the sides.
Cover all external surfaces with masking tape before adding concrete. It gets really messy.
Pour concrete while the print is still attached to the print bed to get a perfect watertight seal at the bottom. This will only work with a flexible print bed like aluminium. It will probably be near impossible to remove from a glass bed.
Use a sponge to level the surface of the concrete.

2019-10-03
The second attempt was a success. As soon as the speaker arrives it will be wired up and tested.

2019-10-22
SPL and impedance measurement added.