Headrest for Aeron Sayl

thingiverse

This is a headrest for Aeron Sayl chair. The only difference from https://www.thingiverse.com/thing:1596840 is the chair attachment. Files from the original design included for convenience. Printing of the parts from https://www.thingiverse.com/thing:1596840 is relatively straightforward, except for the headrestConnector.stl where if you print it with holes aligned vertically you need supports and the far end will sag, so I'd recommend printing it with holes pointing sideways and supports enabled. I went high on perimeters and infill. As for the extra hardware, I went with 50cm M16 rod cut in half and ended up using 3x 60mm M16 bolts, 1x 70mm M16 bolt, 20x M16 nuts, and 8x M16 washers. I found it beneficial to roughen up the 2 washers that go between 2 pieces of plastic with a file to reduce metal on plastic slip. The chair attachment is secured with 2 zip ties, but it wedges into the chair well enough that it's sturdy. The mesh was made from a fishing line, 0,4mm thick, rated for ~16kg. I tied M3 nuts at both ends to lock it in place. To make it tight you can bring one of the side plates closer to the middle, thread it and then use the nuts to bring it to the edge tensing it up. I'd recommend printing 2x https://www.thingiverse.com/thing:4618062 to make the adjustments easy.