Denon DN-HP1000 Swivel

thingiverse

My prized headphones initially started to show signs of distress around a year ago, when a tiny crack appeared on the left swivel. Although I applied crazy glue in an attempt to repair it, my efforts were ultimately in vain as it disintegrated entirely during one of my jogs (yes, I ran while wearing these bulky headphones). As I desperately searched for stray pieces amidst the bushes, a sudden thought crossed my mind - "I can simply 3D print a new one!" This specific part turned out to be more complex than I had anticipated. It's responsible for keeping everything securely attached on the left side and the logic behind its design is both impressive and infuriating. What's more, it boasts features that restrict rotation in two axes. To aid others in the process, I highly recommend partially disassembling the other side as a point of reference. The 3D printing process utilized PLA filament, a 100-micron layer height, and a 0.4mm nozzle on my Robo3D R1 printer. I deliberately left the articulation ring open to ensure smooth assembly without having to remove the lower arm connected to the left driver. Furthermore, I strongly advise partially disassembling the other side to gain a better understanding of how everything fits together. To remove the existing damaged part: Required materials: Needle-nose pliers, soldering iron, tweezers, and an unwavering can-do attitude. Step-by-step disassembly: 1. Unscrew the rectangular clamshell enclosure parts as well as the part in question. 2. De-solder the wires that lead to the right driver. 3. Remove the C-clip holding the brass tube and washer in place. 4. Carefully slide the wires through the tube. 5. Guide the tube through the damaged part, noting that you may need to remove the retention spring first depending on its level of damage. To reassemble: do everything in reverse order while making sure the retention spring is securely positioned in place. Please refer to the other side of your headphones for guidance and inspiration. I'm truly thrilled at the prospect of someone using this custom part - if you decide to, please share photos with me!