For years, the idea of 3D printing an electric guitar danced in my imagination, a seemingly impossible feat. Doubts clouded my mind: Could a 3D printed body withstand string tension? Would it warp over time? Would the sound quality be compromised compared to traditional wood? The internet offered few reassuring answers, mostly filled with more questions than solutions.
While I wasn’t the first to explore this concept, many existing 3D printed guitar designs fell short. Some were visually appealing but unplayable, others lacked readily available models or clear instructions, and some were simply too complex or expensive for the average maker.
This sparked a challenge: I decided to design a 3D printable electric guitar from the ground up, aiming for simplicity and accessibility for the 3D printing community.
Design Priorities: Keeping the 3D Printing Community in Mind
My goal was to create a project that others could easily replicate and enjoy. Before diving into design, I outlined key priorities:
- Simplicity:
- Easy assembly with minimal parts.
- No complex reinforcement structures or specialized hardware.
- Affordability:
- Cost-effective, avoiding expensive components.
- Hardware Accessibility:
- Parts readily available with worldwide shipping.
- Printability on Common 3D Printers:
- All parts must fit on an Original Prusa i3 MK3S+ (25×21×21 cm), a widely used printer size.
- Playability:
- Functional instrument capable of proper tuning and playing across its range, not just a novelty.
- Aesthetics:
- Visually appealing and undeniably cool.
Embracing Simplicity: Design Choices for 3D Printing
The primary concern was the immense force exerted by guitar strings on the body and neck. Estimates suggest around 50 kg of tension, depending on string gauge, constantly trying to bend and break the instrument.
For the neck, the solution was straightforward: utilize a real wooden neck. While a fully 3D printed guitar is a tempting concept, the neck’s crucial role in playability and tuning stability made a wooden neck the pragmatic choice. Wooden necks offer inherent straightness, smooth surfaces, durable frets, and an adjustable truss rod for neck relief.
The bridge, however, required more consideration. The bridge anchors the strings to the guitar body. Examining common guitar designs, the Telecaster bridge emerged as the ideal candidate for a 3D printed guitar. Unlike smaller bridges often held by just two screws, the Telecaster bridge features a large metal plate that not only secures the strings but also integrates the bridge pickup and distributes string tension across multiple mounting points with widely spaced screws.
Image alt text: Telecaster guitar bridge showcasing its large metal plate design, ideal for 3D printed guitar bodies due to its stability and integrated pickup.
The Telecaster’s single additional pickup simplifies wiring and design. Furthermore, volume and tone knobs, along with the pickup selector switch, are mounted on a separate metal plate, further streamlining the project.
This project builds upon previous explorations into 3D printing guitar accessories, including surprisingly effective 3D printed guitar picks and various guitar add-ons like capos and strap locks. These experiments paved the way for this more ambitious undertaking.
Image alt text: Close up of 3D printed guitar accessories, highlighting the versatility of 3D printing for musical instrument components and customization.
Sourcing the Hardware: Affordability and Accessibility
Choosing Telecaster-style hardware opens up several sourcing options:
- Dismantling a budget Telecaster guitar.
- Purchasing individual components.
- Opting for a Telecaster hardware kit.
Disassembling a functional guitar felt wasteful, suitable only for severely damaged instruments with salvageable hardware. Buying components individually, while feasible, quickly becomes expensive, potentially exceeding several hundred dollars even for budget options.
The game-changer for this project was the Harley Benton Electric Guitar Kit T-Style, available for a mere $79! This kit provides all necessary hardware, pre-wired with simple snap-together connectors, from Musikhaus Thomann, a major global music retailer with worldwide shipping. This kit perfectly aligned with the project’s affordability and accessibility goals.
The Harley Benton kit includes a basic, unpainted wooden body, surprisingly included given the price. However, the printed body will replace this, allowing for full customization.
Designing the 3D Printed Body: From Template to 3D Printer Patterns
Fusion 360 was the design tool of choice for creating the guitar body. Accurate placement of screw holes, neck mounting points, and electronics cavities was paramount.
The kit’s wooden body served as a template. By photographing the body with a ruler using a zoom lens to minimize distortion, and utilizing Fusion 360’s “Calibrate” feature, a precise template was created. Tracing hole positions in a 2D drawing and verifying dimensions with digital calipers ensured accuracy, especially for the critical bridge placement. Precise bridge alignment with the neck and correct distance for proper intonation are crucial for playability.
Image alt text: Measuring the Harley Benton guitar body template to ensure accurate dimensions for the 3D printed guitar design in Fusion 360.
While using Telecaster hardware, replicating the classic Telecaster shape felt limiting. 3D printing unlocks limitless design possibilities. Inspired by Fender Jazzmaster and Mustang guitars, spline tools in Fusion 360 helped create a unique, flowing body shape.
Image alt text: Initial Fusion 360 sketch of the guitar body, inspired by Jazzmaster and Mustang shapes, showcasing the organic lines achievable in digital design.
A standard 45mm guitar body thickness was extruded, followed by creating holes and slots for electronics based on the template. Tunnels were designed to connect cavities for wiring. The pickup slots were intentionally oversized for flexibility, as they would be covered by the bridge and pickguard. A larger hole at the bottom edge accommodated the control plate slot and output jack. This completed the basic 3D model.
Image alt text: Extruded 3D guitar body model in Fusion 360, demonstrating the basic form with electronic cavities and initial design elements.
However, the model was too large for most desktop 3D printers, even exceeding the Original Prusa XL’s build volume. Segmenting the model became necessary. Furthermore, the design lacked a distinctive visual element. Exploring 3D printing’s design freedom led to experimenting with 3d Printer Patterns, specifically hexagons.
Hexagonal patterns offered both aesthetic appeal and functional benefits. The numerous edges created by the hexagons provided natural split lines for dividing the model into printable sections. These seams would blend seamlessly into the design, appearing intentional rather than a compromise. A large chamfer along the top edge enhanced playing comfort.
Image alt text: Fusion 360 model incorporating hexagonal 3D printer patterns into the guitar body design, illustrating the aesthetic and functional integration of the pattern for segmentation.
Segmentation for 3D Printing: Strategic Cuts and Printable Parts
Recalling the 50 kg string tension, a crucial segmentation strategy emerged: the section between the neck and bridge should ideally be a single piece. Minimizing joins in this high-stress area was essential for structural integrity.
The hexagonal pattern along the top edge and a cut beneath the bridge mounting holes naturally defined the central piece. A clever angled cut on the bottom left allowed for diagonal print orientation, maximizing print bed utilization on the MK3 and enabling support-free printing. However, Organic supports in PrusaSlicer were used for a smoother finish on overhanging surfaces.
Image alt text: 3D model of the central guitar body piece oriented diagonally on the Prusa i3 MK3 print bed, demonstrating printability within standard desktop 3D printer dimensions.
The remaining sections were split logically along the hexagon pattern and other natural lines to fit within the 25×21 cm print area. The bottom piece, lacking hexagons, was divided into two, and the top section into three.
The pickguard, mounting the top pickup, was shaped by offsetting the surrounding edges by 3mm.
Segmenting the body offered an additional advantage: multi-color printing. Prusa Research’s signature black and orange color scheme, accented with complementary teal, was chosen. The small bottom-right piece in teal provided a vibrant pop of color.
Image alt text: Final 3D printed guitar design with segmented parts and color scheme, showcasing the completed “Prusacaster” model ready for printing and assembly.
The “Prusacaster” model was complete, ready for printing and assembly.
Printing and Assembly: Bringing the 3D Printer Patterns to Life
Material Choice for the Centerpiece: Stiffness is Key
The central piece bears the brunt of the string tension. While PETG might seem like a stronger choice, stiffness (bending modulus) is paramount. Surprisingly, PLA excels in this area and aligns with the project’s focus on simplicity and affordability.
PLA’s temperature sensitivity is a drawback. While the substantial centerpiece can withstand direct sunlight for reasonable periods, leaving the guitar in a hot case on a summer day could be problematic. For higher temperature resistance, materials like Prusament PC Blend Carbon Fiber or Prusament PA11 Carbon Fiber are suitable alternatives, albeit more expensive and challenging to print. Given Prague’s moderate climate, PLA was chosen for its stiffness and ease of use. After a year of testing, the PLA centerpiece remained structurally sound.
A test print of the center piece with default PrusaSlicer settings confirmed fitment. The neck, bridge, and strings were then attached to this single piece – a functional, albeit minimalist, guitar!
Image alt text: Minimalist 3D printed guitar prototype with just the center piece, neck, bridge, and strings, demonstrating early playability testing and structural feasibility.
Addressing Material Creep: Increasing Print Strength
Material creep, the slow deformation of solid materials under sustained stress, was a concern. This proved valid – after a month under string tension, slight bending occurred in the initially printed part. The default PrusaSlicer profile with 2 perimeters proved insufficient. Re-printing the centerpiece with 7 perimeters and 25% cubic infill completely resolved the creep issue.
String Gauge Selection: Managing Tension
Lighter gauge strings are easier to play but produce less volume and are more prone to breakage. Heavier strings offer more volume and sustain but require more finger pressure and exert greater tension on the neck. Opting for thinner, 9-gauge strings reduces stress on the 3D printed centerpiece.
Printing the Remaining Parts: Material Flexibility
The remaining parts experience minimal stress, primarily serving as attachment points for straps and cables. Material choice is less critical here. Prusament PETG Prusa Orange was used for the top hexagon parts, Prusament PLA Galaxy Black for the bottom switch piece, and Prusament PLA Azure Blue for the small bottom piece, all printed with default profiles.
Image alt text: Collection of 3D printed guitar body parts in various Prusament colors, ready for assembly, showcasing the multi-color printing capability.
Assembly: Gluing and Screwing
Generous application of superglue joins the parts, leveraging large contact areas. M3 screw holes in the hexagon pieces provide optional reinforcement, particularly for strap security, although access is somewhat limited.
Wiring the Electronics: Simple Connections
The Harley Benton kit’s JST connectors simplify wiring. Connect the top pickup cables to the selector switch cables, ensuring correct switch operation.
Image alt text: Close-up of the Harley Benton guitar kit’s pre-wired electronics with JST connectors, illustrating the ease of assembly and plug-and-play nature of the kit.
A seemingly unconnected black wire grounds the strings, mitigating buzzing. Route this wire through a channel under the bridge, strip insulation, and secure it by tightening the bridge. This grounding significantly reduces noise.
Image alt text: Diagram illustrating the string grounding cable routing under the guitar bridge, essential for noise reduction in electric guitars.
Final Adjustment: Setting Intonation
After assembly and stringing, tune the guitar and adjust intonation for accurate tuning across the fretboard. Compare open string notes to notes fretted at the 12th fret. Telecaster bridges offer easy intonation adjustment via saddle screws. If the fretted note is flat, move the saddle towards the neck; if sharp, loosen the string and move the saddle towards the bridge. Adjust saddle positions for both strings sharing a saddle, finding a compromise for optimal tuning.
Image alt text: Adjusting guitar intonation on the Telecaster bridge using saddle adjustment screws, demonstrating the process of fine-tuning for accurate pitch across the fretboard.
The Fully Assembled Guitar: The Prusacaster
Image alt text: Showcase of the fully assembled Prusacaster 3D printed electric guitar in various angles, highlighting the final aesthetic and multi-color design.
Playability and Sound: Surprising Performance
The Prusacaster plays remarkably well. Blindfolded, it’s difficult to distinguish it from a traditionally made guitar. Tuning stability and intonation are excellent. While not comparable to high-end Telecasters due to budget components, its performance for the price is exceptional.
Download, Print, and Play!
The Prusacaster project exceeded expectations. If you’re inspired to build your own, download the 3D model from Printables.com:
Download the model from Printables.com
STEP files and a DXF drawing of hole positions are included. The download is free, so embark on your Prusacaster journey and experience the joy of creating your own 3D printed electric guitar!
