A lot of pellet guns come with integrated sound suppressors, one of the cheapest and most popular pellet guns on Amazon does not. The pop of the expanding air at the muzzle isn’t enough for any hearing damage without a silencer, but it could annoy some close neighbors.

I decided to 3D print my own out of ABS filament. I looked at pictures of the insides of different silencers and came up with my own design. It had to be able to mate to the pellet gun’s barrel in some way, fit inside my printer’s print volume, and be designed in a way that would let the baffles print without supports. This is what I came up with in SolidWorks:

The baffles are sloped at 45 degrees to print without supports and the expansion chambers decrease in volume in the direction of fire. The silencer is permanently epoxied to the barrel.

I tested the sound of each suppressed shot and saw a slight drop in sound pressure levels from the unsuppressed shots. The shots are noticeably quieter!

Some places I want to improve this design:

• Quick-detach barrel mount
• Off-axis pellet channel to improve scope visibility
• Optimized baffle spacing (ideally using CFD software)

Email me at wilsonlima5@gmail.com if you have any questions, suggestions, or would like me to send you the files you need to print your own.

While studying at UCF, I had a chance to work on some team competitions as a member of the University's AIAA chapter. One of my most memorable experiences was working on the Aviation Design project where my team and I designed and manufactured a remote-controlled airplane capable of safely carrying a payload of eggs at high speed.

The competition was scored in the unladen performance of the airplanes and in their ability to transport 4-12 eggs around a course in the fastest time. Our airplane scored the fastest time around the course while empty but was unrecoverably damaged before completing the final challenge (A loss of signal between the pilot’s remote and the onboard controller caused a catastrophic crash landing on its second flight).

This project gave me a good introduction to managing a team and designing for manufacturability. Seeing a design go from preliminary calculations:

to CAD:

to assembly:

to flight:

is very rewarding.

If you would like to make your own or take a closer look, you can download the SolidWorks files and a list of parts here.