For years, the dream of crafting a personalized electric guitar using a 3D printer danced in my mind. The concept was thrilling, yet fraught with uncertainties. Could a 3D printed body withstand the immense tension of guitar strings? Would it warp over time, rendering the instrument unplayable? Would specialized pickups be necessary to compensate for a plastic body? And perhaps most critically, could a plastic guitar body even produce a sound comparable to the rich resonance of traditional hardwood? The internet offered scattered attempts, but surprisingly few definitive answers to these crucial questions.
While I wasn’t the first to venture into this exciting territory – online repositories host numerous articles and 3D models, some showcasing impressive results – many of these printed guitars fell short in playability. Some visually appealing projects lacked readily available 3D models, while others were burdened by convoluted instructions, excessive complexity, or prohibitive costs.
Driven by a desire to democratize guitar making and leverage the power of accessible technology, I embarked on a mission: to design my own 3D printable electric guitar from the ground up. This project was conceived with the vibrant 3D printing community at its heart, aiming to provide an easy-to-follow guide for enthusiasts to create their own incredible instruments.
Design Priorities: Crafting a 3D Printed Guitar for Everyone
Before diving into the design phase, I established a clear set of priorities, ensuring the final product would be both innovative and accessible. These guiding principles shaped every design decision:
- Simplicity: The design had to be straightforward, avoiding intricate assemblies of numerous parts. Ease of assembly was paramount, eliminating the need for complex reinforcement methods like metal rods or specialized hardware.
- Affordability: The project needed to be budget-conscious. If significant financial investment was required, purchasing a conventional, high-quality guitar like a Fender or Gibson would be a more practical option.
- Hardware Accessibility: Components had to be easily sourced, with readily available worldwide shipping, ensuring global accessibility for makers.
- Printability on Common 3D Printers: All parts had to fit within the build volume of a widely used printer like the Original Prusa i3 MK3S+ (25×21×21 cm). This constraint, while seemingly restrictive, was crucial for broad accessibility. If the design wasn’t printable on a MK3-sized printer, a significant portion of the 3D printing community would be excluded.
- Playability and Intonation: The guitar had to be more than just a novelty; it had to be a genuinely playable instrument, capable of maintaining accurate tuning across its entire range. Creating an unplayable plastic gimmick was not the goal.
- Visual Appeal: The final design had to be aesthetically striking and visually appealing, showcasing the unique possibilities of 3D printed instruments.
Keeping it Simple: Addressing Structural Challenges with Smart Design
The primary concern from the outset was the immense force exerted by guitar strings on the instrument’s body and neck. While sources vary slightly, the general consensus points to approximately 50 kg (110 lbs) of load, contingent on string gauge (thickness). This force constantly attempts to bend the guitar in half, pull the bridge away from the body, and severely warp the neck.
The solution for the neck was immediately clear: utilize a genuine wooden neck. While purists might argue against a “fully 3D printed” designation, the neck’s critical role and delicate nature made 3D printing it a potentially compromising factor (despite demonstrations of its feasibility). Wooden necks offer inherent smoothness, straightness, durable metal frets, and an adjustable truss rod for relief control (neck curvature).
Addressing the bridge presented a more intricate challenge. The bridge, a small metal component, anchors the strings at the body’s base. Typically screwed into the body, examining common guitar bridge designs revealed one exceptionally well-suited for a 3D printed guitar: the Telecaster bridge.
Unlike most guitar designs with smaller bridges often secured by just two screws, the Telecaster bridge stands out. This substantial metal plate not only secures the strings but also integrates the bridge pickup and boasts up to five mounting holes with widely spaced screws. This design effectively distributes leverage across the plate and the underlying 3D printed body, enhancing structural integrity.
Image: A close-up of a Telecaster guitar bridge, highlighting its large metal plate and multiple mounting screws, illustrating its suitability for a 3D printed guitar body.
Furthermore, the Telecaster’s single additional pickup simplifies wiring and design. Crucially, the volume and tone knobs, along with the pickup selector switch, are mounted on a separate metal control plate, secured to the body with just two screws. This significantly streamlined the project by eliminating the need to individually integrate multiple knobs and switches into the 3D printed body.
Building upon previous explorations, we had already investigated 3D printing guitar picks, which yielded surprisingly positive results. We also experimented with printing various guitar accessories, such as capos and strap locks. These prior projects provided valuable experience and context for this ambitious undertaking.
Image: Assortment of 3D printed guitar accessories including picks, capo, and strap locks, showcasing the versatility of 3D printing for guitar components.
Sourcing the Hardware: Balancing Cost and Convenience
With the decision to utilize Telecaster hardware finalized, the next step involved sourcing the necessary components. Generally, three primary options existed:
- Dismantling a Budget Telecaster Guitar: Purchasing an inexpensive Telecaster solely for its parts.
- Individual Component Sourcing: Acquiring each part separately.
- Telecaster Hardware Kit Purchase: Opting for a pre-packaged hardware kit.
Disassembling a functional guitar purely for parts felt wasteful and counterintuitive, except perhaps in the case of a severely damaged instrument with intact hardware and neck.
Sourcing individual components is a viable route, requiring:
- Guitar neck with tuners
- Standalone single-coil pickup
- Bridge with integrated single-coil pickup
- Telecaster control plate with 3-way switch and two knobs
- Output jack
However, purchasing components individually can quickly become expensive. Even opting for the most budget-friendly options could easily escalate costs into several hundred dollars.
Here’s the game-changer for this project’s affordability and simplicity: The Harley Benton Electric Guitar Kit T-Style! Priced at a mere $79, this kit includes all essential hardware, pre-wired with simple snap-together connectors. Offered by Musikhaus Thomann, a prominent German-based music retailer with global reach, this kit fulfilled the crucial requirement of worldwide shipping.
The kit’s exceptional value and convenience were undeniable. Ordering it transformed the project into a remarkably simple endeavor: “order this kit and 3D print the body parts.” The Harley Benton Telecaster kit includes a basic, unpainted wooden body – an impressive inclusion at this price point. However, I felt no qualms about replacing this rudimentary body with a custom 3D printed version.
Basic Design: Laying the Foundation in Fusion 360
Fusion 360 became my design tool of choice for crafting the guitar body. The critical initial step was accurately mapping all screw holes, the neck mounting interface, and electronics cavities.
The included wooden body from the Harley Benton kit proved invaluable in this process. By placing a ruler alongside the body and photographing it from a distance, ideally with a zoom lens to minimize perspective distortion, I created a precise template. Fusion 360’s “Calibrate” feature allowed me to set the image scale, using the 50cm ruler segment for maximum accuracy and minimal error.
I meticulously traced the positions of all holes in a 2D drawing, utilizing digital calipers to measure feature distances and verify accuracy against the drawing. While all dimensions were important, the bridge position demanded particular attention. Precise bridge alignment with the neck is crucial for string centering, and the bridge-to-neck distance dictates proper tuning. Specifically, the 12th fret should bisect the string length for accurate intonation. While the Telecaster bridge offers intonation adjustment, accurate initial placement is essential.
Image: Measuring the wooden guitar body template with digital calipers, emphasizing the meticulous process of ensuring accurate dimensions for the 3D model.
With mounting holes precisely positioned, the design process transitioned to the creative phase. Despite using Telecaster hardware, I aimed for a distinct shape, moving beyond a simple Telecaster replica. 3D printing liberates design from traditional constraints, presenting an opportunity for unique aesthetics.
Inspired by the Fender Jazzmaster and Mustang shapes, I employed Fusion 360’s Spline tool to create a body outline reminiscent of these iconic guitars.
Image: The initial 2D spline outline of the guitar body design in Fusion 360, inspired by Fender Jazzmaster and Mustang shapes.
Extruding the sketch to a standard guitar body thickness of 45mm formed the basic 3D shape. Subsequently, I extruded holes and cavities for electronics based on the template. Anticipating wiring needs, I subtracted cylinders to create internal “tunnels” connecting cavities. The bridge would cover the bottom pickup slot, and a pickguard the top, allowing for slightly oversized slots. A larger hole on the bottom edge provided access for the control plate slot and output jack. With these steps, the foundational guitar body model was complete.
Image: The extruded 3D guitar body model in Fusion 360, showcasing the basic form with cavities for electronics and hardware.
However, the model’s size posed a significant challenge – it exceeded the build volume of most desktop 3D printers, including even the Original Prusa XL. Sectioning the model into smaller, printable pieces became necessary.
Beyond size constraints, the design lacked a distinctive visual element. Leveraging the design freedom of 3D printing, I experimented with cutouts, ultimately settling on hexagons. This choice was both aesthetic and functional. Hexagons created numerous edges, facilitating model splitting into multiple parts with virtually invisible seams, seamlessly integrating the seams into the design. A large chamfer along the top edge enhanced playing comfort and armrest ergonomics.
Image: The guitar body design incorporating hexagon cutouts and a top edge chamfer, adding visual interest and facilitating model splitting.
Splitting the Design: Printable Sections for Desktop 3D Printers
Recalling the 50kg string tension, a crucial splitting consideration emerged: maintaining a single-piece section between the neck and bridge whenever possible. Strengthening connections between multiple parts in this critical load-bearing area would introduce unnecessary complexity.
Fortunately, strategic cuts enabled this objective. The hexagon pattern defined the top edge, and a cut just below the bridge mounting holes minimized part length. A clever cut on the bottom left allowed for diagonal print orientation, aligning the longest model dimension with the build volume diagonal. This ingenious arrangement even allowed support-free printing for this section, although PrusaSlicer’s Organic supports were ultimately used for smoother overhanging surfaces.
Image: The central guitar body section oriented diagonally on the Prusa i3 MK3 print bed, demonstrating optimized printability and support structure.
Subsequent cuts were more straightforward. The remaining bottom section, lacking hexagons, was split into two printable parts. The top hexagon section was divided into three parts for similar reasons.
The final major component, the pickguard, also serving as the top pickup mount, followed the surrounding edge contours, inset by 3mm.
Sectioning the body offered an unexpected advantage: multi-color printing. Embracing Prusa Research’s signature color scheme, black and orange became the primary palette. Complementing Prusa Orange with a teal/blue accent color on the small bottom-right piece injected vibrancy and visual dynamism.
Image: The final multi-part 3D printable guitar design, showcasing the hexagon pattern, chamfered edge, and color-coded sections in black, orange, and teal.
With this, the “Prusacaster” model was finalized, ready for printing and assembly.
Printing and Assembly: Bringing the 3D Printed Guitar to Life
Material Selection for the Centerpiece: Stiffness is Key
The central piece, bearing the brunt of mechanical stress, demanded careful material selection. While PETG might seem tempting for its perceived “strength,” stiffness (high bending modulus) was paramount. Surprisingly, standard PLA excels in this regard and aligns with the project’s simplicity and affordability goals.
PLA’s primary drawback is lower temperature resistance. While the substantial centerpiece can withstand direct sunlight for reasonable durations, prolonged exposure in a hot case could pose issues. For enhanced temperature resistance, consider stiff, higher-temperature materials like Prusament PC Blend Carbon Fiber, Prusament PA11 Carbon Fiber, or similar alternatives. These materials are more challenging and costly to print. Given Prague’s temperate climate, PLA proved sufficient for this project, and after a year, the PLA centerpiece remained structurally sound.
To verify fitment, I printed a single copy of the centerpiece using default PrusaSlicer settings. Satisfied with the fit, I attached the neck, bridge, and strings to create a functional, albeit minimalist, guitar. Electronics were absent, but it played!
Image: The minimalist 3D printed guitar centerpiece with neck, bridge, and strings attached, demonstrating basic functionality before full assembly.
Addressing Material Creep: Reinforcing for Long-Term Stability
Material creep, the tendency of solids to slowly deform under sustained stress, presented another concern. This concern proved valid. After a month under string tension, the initial print exhibited slight bending. This wasn’t entirely unexpected, as the default PrusaSlicer profile uses only two perimeters – suitable for general use but insufficient for high mechanical loads. Reprinting the centerpiece with seven perimeters and 25% cubic infill completely resolved the creep issue, ensuring long-term structural integrity.
String Gauge Selection: Managing Neck Tension
Guitar strings come in varying gauges (thicknesses). Lighter gauge strings are easier to play and bend but are more prone to breakage and produce slightly less volume. Heavier strings offer increased volume and sustain but require greater finger pressure. Crucially, heavier strings exert more tension on the guitar neck. Opting for lighter gauge strings, such as 9 gauge, can reduce stress on the 3D printed centerpiece, contributing to overall instrument longevity.
Printing the Remaining Parts: Material Flexibility
The remaining body sections experience minimal stress beyond supporting the guitar’s weight and cable connections. Material choice becomes less critical for these parts. I printed the top three hexagon sections in Prusament PETG Prusa Orange, the bottom switch-holding piece in Prusament PLA Galaxy Black, and the small bottom piece in Prusament PLA Azure Blue. Default profiles were used for all these prints.
Image: All the 3D printed guitar body parts in various Prusament colors (orange, black, and blue) ready for assembly.
Connecting the Parts: Adhesive and Mechanical Bonds
All body sections feature large contact surfaces with the central piece. Generous application of superglue securely bonds the parts. M3 screw holes in the hexagon pieces offer optional mechanical reinforcement, particularly useful for strap attachment points. However, screw access is somewhat restricted, making their use optional depending on desired robustness.
Wiring the Electronics: Simple Connections with JST Connectors
The Harley Benton T-style kit’s pre-wired electronics, featuring JST connectors, simplify wiring significantly. Connecting components is as easy as snapping connectors together. Ensure correct connection of top pickup cables to the selector switch to avoid reversed switch operation.
Image: Close-up of the pre-wired Harley Benton guitar kit electronics with JST connectors, illustrating the ease of assembly.
A seemingly unconnected black wire in the wiring harness serves a crucial purpose: string grounding. A channel in the 3D printed centerpiece runs beneath the bridge for this wire. Strip insulation, slightly loosen the bridge, route the wire through the channel, and crimp it by retightening the bridge. This grounding significantly reduces unwanted buzzing, a common issue even in higher-end guitars, especially when using budget components.
Image: Diagram highlighting the grounding wire routed under the bridge, essential for minimizing guitar buzz.
Final Adjustment: Setting Guitar Intonation for Perfect Tuning
With the guitar fully assembled, stringing and tuning precede intonation adjustment – ensuring accurate tuning across the fretboard. After tuning, compare the open string note to the note at the 12th fret. Significant pitch discrepancies indicate intonation adjustment is needed. Telecaster bridges simplify this process. Adjust saddle position (string height adjustment piece) by turning its screw. If the fretted note is flat, move the saddle towards the neck; if sharp, slightly loosen the string first, then move the saddle towards the bridge. Telecaster saddles often serve two strings, requiring a compromise for optimal intonation of both.
Image: Close-up of intonation adjustment on the Telecaster bridge, showing saddle screws and string position.
The Fully Assembled 3D Printed Guitar: The Prusacaster
Image: Three images showcasing the fully assembled 3D printed Prusacaster guitar from different angles, highlighting its unique design and color scheme.
Playability Assessment: Exceeding Expectations
The Prusacaster’s playability is genuinely surprising. Blindfolded, one might mistake it for a conventionally manufactured guitar. Tuning stability is excellent, and intonation is remarkably accurate. While not expected to rival high-end Telecasters due to budget components, the Prusacaster delivers exceptional performance for its cost, proving the viability of 3D printed instruments.
Download, Print, and Play: Make Your Own Prusacaster!
Overall, the Prusacaster project exceeded all expectations. To empower you to create your own, the 3D model is available for free download from Printables.com: Download the 3D model from Printables.com. The download package includes STEP files for all parts and a single-piece basic guitar design, along with a DXF drawing of hole positions for customization.
Download the model from Printables.com
As always, this resource is freely available. Embark on your own Prusacaster journey and experience the joy of building a unique, 3D printed electric guitar!
