Hifiman HE 400i and HE 560 headband fork replacement

thingiverse

The Hifiman HE 400i's and HE 560's are notorious for having their forks break. I'm no exception, so I decided to take matters into my own hands and print out a replacement. I tested various materials and have listed them below for your convenience: PLA: It holds up surprisingly well, but the material is rather stiff and brittle. I would recommend something with more flexibility. ABS: This is what I'm personally using - Matterhackers' burgundy ABS. It has good flex, is stiff enough to hold its shape, and offers excellent temperature resistance. PETG: A great alternative to ABS, it has a bit more flexibility, which may be desirable. However, it has less overall temperature resistance. Nylon: Unfortunately, it's too flexible and doesn't provide enough clamping force to stay on reliably. I've been using the ABS parts shown in the picture (the burgundy one) for over 6 months now, and they've proven to be much more durable than the stock forks. To replace your forks, you'll need to unscrew the plastic hinge that attaches to the swivel point of the forks. Then, rotate the forks to release the adhesive holding them together. Next, attach the forks to the earcups (they have enough flex to be stretched and snapped into place). Finally, put them into the hinge and screw them back on. You can expect to see various pictures showcasing different colors as well as the fit of the swivel part.