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When Sound takes Shape

3D printing turns a Sound Idea into a Mass-Produced Product

The Fliphead is a novel mouthpiece that playfully combines the transverse flute and saxophone. Developed by professional saxophonist Axel Müller, it evolved from a handmade one-off piece into a product ready for series production with the support of 1zu1scale. Smooth surfaces, food safety, consistent sound quality, and economical series production using SLS 3D printing were decisive factors.

Music is extremely sensitive—even the smallest deviations change the sound. With precise SLS printing, CT analysis, and clean post-processing, we were able to consistently translate the idea into a product ready for series production.

Stefan Rädler,Division Manager Additive Manufacturing

Innovative Mouthpiece for new Ways of Playing

The Fliphead is used as a mouthpiece on the transverse flute and fundamentally changes the playing position. The recorder-like blowing technique makes learning easier and creates a new, unique sound. The air channels, precision-manufactured using the SLS process, are crucial for sound, response, and repeatability—factors that would be difficult to achieve with conventional manufacturing methods.

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Components

One-piece mouthpieces in SLS 3D printing made from PA12

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Properties

Food-safe, robust, and temperature-resistant

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Scaling

Series calls in high annual quantities

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Additional Services

Color scheme and logo printing without dimensional deviation

SCALE: One Process, many Advantages

Sketch

Sound meets concept

  • The starting point was the idea of an innovative mouthpiece with a defined sound profile
  • Initial prototypes served as acoustic references
  • Focus on geometry, airflow, and function

Check

Sound scientifically tested

  • Analysis of prototypes using CT scans
  • Testing of function and sound reproduction
  • Iterative optimization of geometry and precise air channels
  • Design specifically for SLS manufacturing

Approve

Technology determined

  • Final technology decision: PA12 using the SLS process
  • Decision on the EOS P500 for series production capability and consistent quality
  • Design freeze: validated sound and functional design

Launch

Series process established

  • Establishment of a stable series process
  • Ensuring reproducibility and material quality
  • Preparation for series production, including post-processing

Execute

Serial sound in perfection

  • Series-ready production of mouthpieces
  • Dyeing and printing as integrated process steps
  • Result: consistent sound reproduction – identical to the original prototype
  • Marketable product with series quality and repeatability

A result that is impressive

Together with Axel Müller, 1zu1scale has successfully developed the Fliphead from a handmade one-off to a music accessory ready for series production. Professional SLS 3D printing ensures consistent sound quality, food safety, and cost-effective manufacturing—turning a creative idea into a market-ready product.

The fliphead should be made from a single piece, be affordable, and always sound exactly the same. At 1zu1scale, I found exactly the quality and proactive approach that was needed to achieve this.

Axel Müller,Inventor of the fliphead and professional saxophonist

Questions & Answers

An alternative mouthpiece for the transverse flute that enables a new playing posture and a unique sound.

3D printing allows for a one-piece design, free configuration of the air ducts, and cost-efficient series production without tools.

PA12 in the SLS process – food-safe, robust, and temperature-resistant.

Through precise process control, CT analysis of the air ducts, and high repeatability in SLS printing.

Dyeing by hot pressure impregnation and optional printing with logo.

Technology & design consulting, series production, finishing, and quality assurance.

Project Managers

From idea to series: The people behind the project.

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