1920's Radio Headphones, Ear Cup Replacement via 3D Printed Replicas

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1920's Radio Headphones, Ear Cup Replacement via 3D Printed Replicas These ear caps were crafted for Brandes brand headphones manufactured sometime in the 1920s. These parts are designed to replace very early radio headphones made from Bakelite. The ear cups are printed in two pieces, then glued together, and after that, sanding, painting, or applying epoxy smoothes out the surface to resemble the smooth finish of original Bakelite components. Additional files for 3D printing some sanding arbors are also provided: one is optimized for a lathe and another for a 3/8 drill chuck. A YouTube video details the process of creating ear cap replacements, available at https://youtu.be/-7h8EQaEMt0. The most notable challenge is that threads are extremely fine and close to the limit that can be printed with an FDM printer. Using more fan cooling, a slightly higher extrusion temperature, and much lower print speeds significantly improves the outcome. It appears that the age of the plastic also plays a role; newer materials produce better results. Some light stringing at the threads may require cleanup after printing. It might also be necessary to adjust the scale slightly for optimal fit, so multiple printings may be required to achieve success.