Gallery
About Project
Why hide a speaker inside an ordinary box when it can arrive looking ready for the road? This custom audio product transforms a full-size tire form into a bold sculptural speaker, complete with deep tread blocks, a dark textured surface, and a driver positioned at the center like an oversized wheel hub.
The enclosure was manufactured directly through Binder Jet sand 3D printing, without producing a conventional mold or casting the final body. This tool-free approach was especially suitable for the large circular form and deeply patterned surface, which would be costly and time-consuming to reproduce as a one-off or limited-run product with traditional tooling. The naturally granular finish also works beautifully with the tire concept, giving the enclosure a convincingly rugged appearance instead of making it look like an ordinary plastic shell.
Its substantial size, distinctive texture, and comparatively economical large-format production make this approach attractive for outdoor displays, themed venues, events, and other public-facing creative products. The finished enclosure feels visually tough and substantial, while its unconventional shape makes the speaker an immediate conversation piece. For prolonged exterior use, the coating, joints, wiring, and electronic components should still be specified with appropriate weather sealing and water protection. Planning a custom speaker, outdoor installation, or oversized sand-printed product? Send your files and requirements to info@facfox.com, or request a custom manufacturing quote online.
Solution
- Step 1: The digital tire enclosure was reviewed for overall dimensions, wall thickness, tread depth, balance, driver clearance, mounting points, cable routing, and base contact.
- Step 2: The model was prepared as printable components with accessible openings for removing loose sand from the enclosure and internal passages.
- Step 3: The enclosure was produced by Binder Jet sand 3D printing, with the surrounding powder naturally supporting the circular body and tread geometry.
- Step 4: After curing, the printed components were carefully removed from the powder bed and thoroughly depowdered using brushes, suction, and controlled air.
- Step 5: Epoxy resin was infiltrated into the porous sand structure to bind the particles more securely, improve handling strength, and prepare the surface for finishing.
- Step 6: The enclosure was prepared and spray-painted in a dark tire-like finish while retaining the characteristic granular texture.
- Step 7: The speaker driver, base, and related hardware were installed and secured, followed by checks of fit, stability, wiring, appearance, and basic audio operation.
- Step 8: For extended outdoor service, additional weather-resistant coating, sealed joints, protected connectors, drainage planning, and suitably rated electronics are recommended according to the installation environment.
