Bluetooth Headphones

thingiverse

I designed my own Bluetooth headphones using OnShape and printed everything at 100% infill with no supports on the headband, where the wires go through. The cups were printed face down to achieve a smooth finish, requiring less sanding. The headband was laid flat, eliminating support needs. The cushion and driver holder can be printed anywhere since they're not visible after attaching the cushion. You need to print five parts: the power side, audio side, two driver housing units, and the headband. Here are the components I used: * Dayton Audio 40mm speaker drivers * CSR8645 Bluetooth chip from Aliexpress * Li-ion Battery Pack from Jaycar * DPDT power on/off switch from Jaycar * Hook up wire from Jaycar * Tactile switches for volume control from Jaycar * Hot glue to secure parts and attach cups to the headband * Model glue to bond parts together * Paint of your choice, with Dulux plastic primer spray and colors from their range * Sandpaper for a smooth finish before painting * Soldering iron and solder * Lithium battery charging module from eBay I used Bose replacement cushions. If you find these components elsewhere, go for it. If you decide to make these headphones, post them on this platform. I'd like to give a huge shout out to Shannonley on Thingiverse for his homebrew headphone website, which I highly recommend checking out when you have the chance.