OnShape fix of Broken Headset Clamp - MDR-XB650BT

thingiverse

### Problem My SONY MDR-XB650BT broke during quarantine, which is an unfortunate situation when you have to be constantly on calls. ### CAD Solution I designed a clamp for it to hold the broken part in place by measuring dimensions and using PTC's OnShape web-based CAD tool. You can sign up for free at https://www.onshape.com/. Since the tool is free, I'm sharing the actual CAD design with you: [CAD Model of Headset Clamp](https://cad.onshape.com/documents/e66685191611ab7a88524a2c/w/ad6e113b5e2d46fc67a1ec37/e/2841af7a6a86b59a654c60fa). ### Versions The first version I created was an extruded part with some fillets to make the edges less sharp. I added a logo to make it fancy and printed it as draft. Unfortunately, the curvature of the bands - being a circle with 16cm diameter - still caused uneven sitting, forecasting that the clamp would eventually fall off again. The second version has a bent shape accurately aligning to the curvature of the band. This version sits perfectly! So perfect, I decided to put one clamp on the healthy side of the headset for a symmetric look and feel. The final print in black looks great, and the print itself snaps tightly into place.