3D printing is a powerful tool that allows inventors, engineers, and creatives to bring their ideas to life, transforming concepts into tangible realities. For Tom Rothbauer, an experienced engineer with decades of work in manufacturing, product, project, and design engineering across Indiana, Illinois, and Michigan, this technology has opened new doors for his long-standing passion for music and craftsmanship.
Tom’s love affair with the hammered dulcimer began nearly 40 years ago when he first encountered the instrument at a folk music festival. Captivated by its unique sound and beauty, Tom was drawn to its rich, melodic tones. The hammered dulcimer—a stringed instrument played by striking the strings with small hammers—piqued his curiosity, though at the time, Tom had no formal musical training.
Five years later, while on a vacation in North Carolina, Tom stopped at a music store and purchased his first hammered dulcimer. Determined to learn how to play, he immersed himself in the music, spending years listening to melody cassettes of the instrument. It took Tom three years to master his first song, “Silent Night.” As his musical journey continued, he found himself frustrated by the limitations of his instrument—it simply didn’t have the right notes to play the full range of songs he envisioned.
Instead of letting these constraints hold him back, Tom decided to find or create a hammered dulcimer that met his specific needs. After years of seeking out builders from around the country, only to face disappointment with the results, he realized that the only way to achieve his vision was to build the instrument himself.
Tom dedicated eight years to designing his ideal dulcimer. By 2014, his design was complete. He built the instrument using a mix of high-quality woods, including mahogany, hard maple, walnut, Baltic birch, and poplar. These materials were carefully selected for their ability to produce a rich, resonant sound, and to create a durable, functional instrument.
Earlier this year, a friend introduced Tom to the LPCPL Exchange. At first, he didn’t think the space could help him make anything substantial, but he was intrigued by the possibilities offered by 3D printing, particularly when it came to creating custom hammers for his dulcimer.
Tom knew that a good hammer grip was essential for balance and understood the importance of keeping the hammers lightweight to facilitate quick and effortless play. Determined to find the perfect design, Tom embarked on a journey of trial and error, experimenting with different sizes, shapes, and materials for the hammerheads.
After several rounds of testing and fine-tuning—adjusting the diameters of the hammerheads, experimenting with varying density of infill, and refining the design—Tom finally arrived at a combination that worked for him. Today, he has created over 12 sets of six hammers in a variety of colors, shapes, and sizes, ranging from vibrant yellow and orange to sleek black and transparent clear.
Though Tom doesn’t perform publicly, he takes great joy in demonstrating his hammered dulcimer to others whenever the opportunity arises. His journey—driven by his engineering expertise, passion for music, and a relentless pursuit of perfection—demonstrates the power of combining craftsmanship with cutting-edge technology like 3D printing.
Tom’s story is a testament to how innovation can help bring creative visions to life. 3D printers are only one example of several tools and machinery available for training and use at the LPCPL Exchange.
To learn more about the Makerspace, equipment, and trainings, please visit https://www.laportelibrary.org/makerspace.