Headphone Cushion Mold

thingiverse

Frustrated with constant headphone cushion replacements, I set out to create a mold for casting custom cushions from silicone or silicone foam. Specifically designed for Beats headphones with a diameter of 70x65 mm once the original cushion is removed, this mold proved to be a game-changer. Using Smooth-On Dragon Skin FX-Pro, which happened to be on hand, I began by closing the small hole at the bottom of the mold with some tape to prevent any unwanted leakage. Next, I carefully opened the mold about 1 cm and filled it halfway with silicone before placing the center piece in its correct orientation and sealing the mold with a tight fit using 2x45mm M3 screws. Additional silicone was added as needed, and a heavy flat object was placed on top to ensure everything stayed put. Using a screwdriver on both sides, I slowly opened the mold, revealing my newly created cushion within. In total, approximately 80-90ml of silicone was required for this project. Unfortunately, the accompanying jpgs and stls failed to display properly in the viewer, leaving me hopeful that Thingiverse will resolve this issue soon.