Logitech G230 / G430 Headphones ear cup modification

thingiverse

I've inherited "Elf Ears" from Dad. Thus, locating headphones that fit comfortably without flattening my ears has proven to be a challenge. I opted for Logitech headphones to see if they would accommodate me. Unfortunately, they were too small, so instead of returning them and trying other models, I chose to design a modification. This is how it all began. Designing the Mod The Design Origin: Firstly, I scanned my headphones using a flatbed scanner, which surprisingly yielded an accurate image. Then, I went into GIMP and carefully removed the background until only the outline and screw holes for the earcups remained. I transferred the resulting image to Inkscape where I performed a bitmap tracing operation to obtain an SVG format file. The design was refined slightly before exporting as an SVG file. I then imported the SVG file into Blender and initiated a series of extrusions, shrinking certain layers while adding more material in other areas until achieving the desired outcome. TIP: When transferring files from Inkscape to Blender, you must scale the SVG by a factor of 1004 times in both the X and Y directions. This process produced an adequate result for printing purposes. A duplicate design was created, and one side was mirrored across the X-axis (using Ctrl + M followed by 'X' for the x-axis mirror) to ensure symmetry before exporting the modified designs as STL files. One file contained data for each earcup, and they were then printed out to produce custom-fitted headphones that finally fit my "Elf Ears." Scan of the headphones Removing background noise and making a few adjustments resulted in an acceptable scan image