Over the decades.. I've had countless headphones as a heavy user. Cables end up breaking, cup arms snapping or bad internal connections were you suddenly miss left or right audio are all common problems. The biggest problem these days however is the cost of decent headphones being obscene. Designing my own headphones is something I've thought about for many years and since my SteelSeries 4H finally give up on life after being patched and bodged countless times.. I figured now is a good a time as any!
For this design I am salvaging the SteelSeries 4H speakers meaning I only need to buy foams and that is it. However any decent 40mm speaker will do, just you get what you pay for like most things.
The design is entirely based around zero supports required to print, short print times and easy to switch out components in a modular fashion. That is why the speakers are designed in their own cradle which then screws to the cup so if something goes wrong its mega easy to change, switch out the speaker mount for a different design or anything I want.
As for the ear cup foams and headbands I'm using a replacement set I got for £11 off amazon meant for Amazon G series headphones, so I'm not skimping on comfort either!
The 3D files I'm still tweaking for uploading to Thingiverse. Follow the Facebook page from the top menu link for a notification when available. Here is an exploded diagram view of all components being printed.
The cups feature the removable speaker mount and a cable retainer clip. I HATE headphones that have a knot inside the cup to stop you snagging the wire, this is where breaks in cables often happen.
The first printed cup prototype which turned out to be so spot on that I didn't bother reprinting them again as there was no need.
The rear of the cups are smooth finished.
The first speaker test fitted in place to check fitment and again it just pushed fit in place so snug that no glue or such is required.
To fit the Logitech G series foams to this design I used cardboard to make a template of the shape. Scanned the template and then imported it in 3D. This meant when I created the 3D version it was millimetre perfect.
Version 1 of the top plate with the foam fitted showing the template worked perfectly.
Back to the speakers to now solder up cables. I'm using a 3 meter audio cable which can be replaced without taking the other cup apart at all.
Both cups fully soldered and working.
Designing the headband is a bit more tricky and why I'm not realising the files just yet. It needs to suit my head shape and while measuring your own head with a bit of string is easy... getting the shape side on by yourself is quite difficult.
Truthfully it took 5 versions of the headband before I finally nailed the design. It needs to be flexible enough to put on / take off my head, strong enough that it pushes the cups against my head but not too hard and durable. 3MM ABS filament at 100% infill was used and the arms are attached separate so I can design or reprint single components in the future.
Both cups fully complete with foams ready to use.
Test fitting the pivot arms in the cups to ensure they pivot without resistance but also aren't loose that eventually it'd break the parts.
Version 2 of the top plates for the foams as version 1 lacked bass where the cup was far too open. Version 2 seats against the speaker mount and stands off the cup by 2MM allowing the foam leather retainer to slip around.
Test fitting the new top plates with foam and the bass low end has improved massively, perception of louder volume with it also.
The top headband requires the Logitech head foam band which is mounted on a 1MM thick ABS plate thin enough to be flexible but sturdy enough it won't just bend when putting it on my head.
Finally complete! My own 100% bespoke headphones which if any single part fails I can simply reprint. If I'm unhappy with a part then tweak the design and.. reprint. No more buying stupid priced headphones!