I have a pair of headphones. The sound is still good, and they are comforatable to wear. So comfortable that in the last 10 years the plastic components on the ends of the ring to maintain the ear pieces have broken and been repaired with epoxy, nuts & bolts, JB Weld, string, tape, etc..
It's about time that I print out new ones

Upgraded 2012-07-17:
Adjusted the shape based on a fit test. The hanger is less tall, and is without removing the rubber bumpers wider because the original didn't fit over the ear pieces.
I suspect I might need to refine the arm-end pieces and shrink both them and the toggle eventually.

Upgraded 2012-07-12:
I guess that the original version had a diameter used as a radius by injury. I have corrected that, but now it looks too small. Even if the radius of the exterior of the ear-piece is correct the connectors seem way to beefy in contrast. Perhaps I should just go with it and add a few personalized decoration... either that or try to slim it down closer in size to the first part.
Ok, slimed it down now. Looks better.


I have not tested the build yet. My plan was to use ABS and use slurry to weld the two halves of the arm-ends set up with the toggle there.
Just a warning - the arm-end pieces do not quite lie on a level surface in the STL files. I might have it shut in the -all file, as I attempted to calculate the angle, but I would not count on it. Cura has a command I was planning to use to fix that before I print.
Some support will be required for probably, and the hanger the toggle.

Related designs