Introduction: How to Make an Ultra-Thin, Unique Tweeter From the Thinnest Foil — Inspiring DIY Project

By romanursuhack
About: https://www.youtube.com/dashboard?o=U

Welcome to this Instructables on DIY ribbon tweeters, where we explore the fascinating process of creating your own high-performance speaker components. Ribbon tweeters are known for their exceptional ability to reproduce crystal-clear high frequencies, and building one yourself combines science, craftsmanship, and a touch of engineering brilliance.

Supplies

Membrane:

  1. Aluminum foil, aluminum adhesive tape, or polyester film (e.g., Mylar).

Magnets:

  1. Neodymium magnets (various sizes and strengths based on the design).

Casing:

  1. Wooden sticks (e.g., popsicle sticks) or plastic 3D MODELS(depending on your preferred construction)
  2. Below, I have attached two files for downloading the 3D models.

You can order 3D models on JLC3DP with a great discount by using my link. JLC3DP 3D Printing starts at $0.3, Up to $60 new user coupons：https://jlc3dp.com/?from=RUH3D #JLC3DP

Adhesive:

  1. Aluminum tape or double-sided adhesive tape.

Wires:

  1. Copper wires for electrical connections.

Soldering Flux:

  1. Specialized flux for soldering aluminum.

Epoxy Glue:

  1. Two-part epoxy for strong and durable bonding.

Step 1: 3D Design and Ordering the 3D Print

First, I designed the 3D model of the gears and the 3D model of the tweeter casing. Then, I uploaded them to the website JLC3DPhttps://jlc3dp.com/?from=RUH3D, and within a very short period of time, I received a package with the ready-printed parts, all with amazing quality!


Please note that the magnet sizes in the casing slightly differ: one side is designed for 10 mm magnets, while the other is for 9 mm magnets. Make sure to adjust the magnet slots to fit your sizes and double-check the files before printing.

Attachments

Step 2: Install the Magnets

Install the magnets by gluing them with a two-component epoxy adhesive. Pay attention to the correct polarity alignment. If something is unclear, check out the detailed instructions in the YouTube video attached to this post, where all the steps of the process are thoroughly explained.

Magnets in sound tweeters create a magnetic field that interacts with the conductor, causing it to move and produce sound. Ribbon and planar tweeters typically use powerful neodymium magnets, which ensure the precision and clarity of sound waves, especially in the high-frequency range. The quality of the magnet directly affects sound reproduction, reducing distortion and improving sensitivity.

Step 3: Making the Diaphragm

To make the diaphragm from thin aluminum foil and two gears, the foil is cut to the required size. The foil is then placed between gears with fine teeth, which, through pressure, create ribs on its surface. These ribs give the diaphragm the necessary rigidity and help improve acoustic characteristics by controlling vibrations and minimizing sound distortion. This method allows for the creation of a lightweight and flexible diaphragm, ideal for tweeters operating at high frequencies.

Step 4: Final Assembly

At the final stage, install the aluminum diaphragm and solder the wires using a special flux for aluminum soldering. Be careful not to damage the diaphragm during installation, as it is very thin.

The homemade tweeter works by the interaction of the magnetic field with the conductor, causing it to move. When the diaphragm is subjected to vibrations, it begins to oscillate, creating sound waves. These vibrations travel through the air, forming high-frequency sounds. The aluminum diaphragm used is lightweight and flexible, allowing for precise transmission of high frequencies while minimizing distortion. The entire system is tuned to effectively transmit clear and accurate sound waves in the high-frequency range.

Step 5: TEST

Unfortunately, I wasn't able to conduct a full test of the high-frequency tweeter, as it was connected to the standard output of an amplifier and a vinyl record player. As a result, during bass playback, you can hear a distinct clicking sound in the video, which indicates that the tweeter is not designed to handle low frequencies. To compensate for this, I reduced the amplifier volume to somewhat reduce low-frequency distortion. Despite these limitations, you can still appreciate how loud and clear this miniature tweeter transmits sound waves. This highlights the impressive acoustic capabilities of the device, despite its size and frequency range limitations.


In my video, there's also another method for making a high-frequency tweeter using wooden sticks. It's an alternative approach that might interest you with its simplicity and unique features. Head over to my YouTube video and check out the continuation to learn more about the process and results. Thank you for watching!