Background

3D Hub was tasked with developing the AC75 Microphones specifically for use on AC75 boats in the America’s Cup, a competition that demands highly robust and reliable equipment. These microphones needed to function in harsh marine environments, including being submerged underwater for periods and quickly draining water. They also had to be sensitive enough to capture clear audio of conversations and ambient sounds while withstanding wind speeds of up to 100 km per hour.

Solution

The design process was driven by the need for a versatile microphone that could be installed in multiple locations on the boat, such as the cockpit, bow, and stern, to capture a wide range of audio, including water sounds, conversations, and boat noises. To achieve this, 3D Hub employed a hands-on, iterative approach involving rapid prototyping, testing, and material experimentation.

A unique aspect of the development process involved testing the microphone housing's shape using an electric leaf blower. By applying Bluetac to adjust the housing, the team experimented with how airflow transferred from the housing onto the foam. This method allowed for easy adjustments to the airflow angle, effectively simulating the conditions the microphones would face on the boat.

The key materials chosen included:

• Open-cell foam: Used to reduce wind noise while allowing water to drain quickly.

• MJF-printed PA12 Nylon: Selected for the microphone housing due to its excellent mechanical properties.

• Soft rubber-like material: Used for the microphone holder to minimize vibration transmission.

The development involved innovative manufacturing processes such as 3D printing, vacuum casting, and precision cutting of the foam. A significant challenge was assessing the audio performance within a tight timeframe and budget, which was overcome through creative testing methods and close collaboration with audio engineers, who played a crucial role in refining the design.

Results

The AC75 Microphones were directly commissioned for use in the America’s Cup and integrated seamlessly into the AC75 boats’ design. Despite the lack of a traditional market launch, the microphones have received overwhelmingly positive feedback, especially for their ease of installation, robust design, and effective performance in extreme conditions. While formal testimonials are yet to be collected, initial responses have praised the microphones' functional and aesthetic integration.

This case study highlights the success of the AC75 Microphones in addressing the specialized demands of high-speed marine sports and showcases 3D Hub's ability to deliver tailored, high-performance solutions under challenging conditions.