Carbon Fiber Instrument Crafting
Session Number
Project ID: ENGN 05
Advisor(s)
David Hernandez, Illinois Mathematics and Science Academy
Discipline
Engineering
Start Date
17-4-2024 8:55 AM
End Date
17-4-2024 9:10 AM
Abstract
This experiment seeks to determine whether carbon fiber is a viable alternative to brass, wood, or nickel in woodwind construction. The benefits of using carbon fiber include weight reduction, rigidity, and price reduction when mass-produced, resulting in access to affordable instruments for the underprivileged. The primary downside and reason that this is the first saxophone of its kind is that carbon fiber does not shape or tune like its brass or wood counterparts. We constructed a conical tube with a bell and a tone hole, and when paired with a tenor saxophone neckpiece, the instrument should be capable of playing four notes, two down the octave and two up. Many different mold types were tested, with the best solution being an interior 3D-printed mold that chips away when exposed to high temperature and pressure, applied during the second phase of production: autoclaving the instrument. Autoclaving also removes impurities from the resin coating on the carbon fiber. Post autoclave, excess resin and fiber are filed off of the horn, also forming the tone hole that is strategically placed during the molding process. The result is a functioning instrument capable of playing four notes.
Carbon Fiber Instrument Crafting
This experiment seeks to determine whether carbon fiber is a viable alternative to brass, wood, or nickel in woodwind construction. The benefits of using carbon fiber include weight reduction, rigidity, and price reduction when mass-produced, resulting in access to affordable instruments for the underprivileged. The primary downside and reason that this is the first saxophone of its kind is that carbon fiber does not shape or tune like its brass or wood counterparts. We constructed a conical tube with a bell and a tone hole, and when paired with a tenor saxophone neckpiece, the instrument should be capable of playing four notes, two down the octave and two up. Many different mold types were tested, with the best solution being an interior 3D-printed mold that chips away when exposed to high temperature and pressure, applied during the second phase of production: autoclaving the instrument. Autoclaving also removes impurities from the resin coating on the carbon fiber. Post autoclave, excess resin and fiber are filed off of the horn, also forming the tone hole that is strategically placed during the molding process. The result is a functioning instrument capable of playing four notes.