Hi guys,
I've been reading the posts around here for a while, and I figured you'd be interested in this (my apologies if it's a repeat, but I did not see it posted previously).
At this link you will find the patent for RPG Inc's BAD Panel, with detailed drawings and lots of detail. It's nice to have a printed copy on hand, so I utilized my printer.
The build does not look complicated -- just time consuming.
Also, here's some additional information that is not included in the plans that I found by rooting around on the internet:
1) In the plans, it looks like the binary holes are "rectangular." However, it looks like RPG is actually building these using 1/2 inch or 5/8 inch circular holes instead of rectangles, probably for ease of manufacture. The measurements on their site are for the 1/2 inch hole variety.
2) The 1/2 inch holes seem to offer both the best absorption and the best diffusion.
3) I believe I read on RPG's Website that their panels are made from high density fiberboard with a density not less than 90 pounds pcf. That's some heavy stuff, and I have not been able to find a good match at Home Depot or the like. According to the patent, in an ideal world, the absorping parts of the panel would be 100% absorbent and the reflective parts 100% reflective, but they do acknowledge that in the real world, we'll obviously have to settle for less. Still, they are making them from 90 lb. pcf material, so I would think that's a good target.
Enjoy:
Patent US5817992