AEG has several sources of sound: motor and gearbox sounds, piston sound, and muzzle pops
- Motor and gearbox sound is mostly generated by meshing of gears and all the little mechanisms rattling, which can be minimised from source with shimming and tuning the overall rigidity of the system. Normally this is transmitted via resonance or reverberations through the gearbox and AEG body itself, so if you can dampen this vibration around the receiver area this can be reduced.
- Piston sound is a loud pop from the piston hitting the cylinder head. Similarly this can be dampened however you want with piston head + piston head combos/trickery, or something done to the cylinder or gearbox or receiver to dampen the vibration and transmission.
- Muzzle pop is probably not as loud as the above, but first you want to contain the expanding volume of air, and secondly dampen the vibration from being transmitted via the smooth cylinder shape of the suppressor.
These are all essentially sound insulation problem and there are several principles for dealing with this. Sound travels through air so any unnecessary air gap can be sealed to contain sound, but this is perhaps not practical for an AEG. Mass absorbs sound, so in theory filling your receiver and suppressor with concrete would be best but obviously this is not practical. Another way is material science, make it less resonant so it absorbs the vibration (i.e. sound) instead of transmitting it into the air, usually this means a suitably soft material, or even better, a composite material like applying 3M 2552 Damping Foil Tape so the vibration is turned into heat rather than being allowed to vibrate freely thus transmitting into the air.
Foam does not do much because while it slows the expanding air, it does not really dampen much vibration of the aluminium can that is holding it.
So in theory perhaps the best airsoft suppressor will firstly have damping foil applied to interior (to deaden the can body), and then layers of heavy weight acoustic rubber floor matting (the type used for soundproofing floors, use heaviest grade you can find), then the inner most post leave just enough diameter for some baffles (material doesn't matter) to allow the air to expand and be slowed before it travels towards the end of the can, you only need maybe about the same volume of the gearbox cylinder or even less.
Then if you put some damping foil on (inside) the receiver and gearbox and cylinder(I have some on my motor) then it will be even quieter, if you are going for ultimate stealth SD6 build.
Somewhat relevant video
https://www.youtube.com/watch?v=SK9qpGqBBmg you don't need a whole lot to be effective.
Only downside is the 3M stuff is expensive and I am still looking for alternatives. This is not normal aluminium foil tape because this stuff has 0.254 mm thick aluminium (~250 micron) as opposed to the 30 to 50 micron thick common stuff, and you can't just double up the normal stuff because it doesn't work that way.