Replacement Headband for Koss KPH30i

prusaprinters

<p>The headband of my Koss headphones snapped, so I made this replacement. It clamps a bit less with my filament and ditches the size adjustment.</p><p>The .stl fits MY head, that is very big - nearly maximum of the original size adjustment.</p><h3>Assembly</h3><ul><li>Print with recommended settings</li><li>Cut the drivers from the original headband as seen in the picture</li><li>Transfer the silicone headband from the original to the replacement</li><li>Insert the drivers into the slots, check fit and clamp on your head, glue them in</li></ul><h3>Customizing for your head size</h3><p>Don't scale the .stl in the slicer! The silicone headband won't fit anymore.</p><p><strong>My head is bigger!</strong></p><p>Super easy: Just don't insert the original parts into the slots completly and glue them as needed.</p><p><strong>My head is smaller!</strong></p><p>Shorten the slot length of the 3D-print and the headband stub of the drivers. You can easily shorten the slot length in the Fusion360 source file as well.</p><p><strong>Other customizations</strong></p><p>e.g. headband thickness (clamping force), clearance in the slot, position of the silicone headband...</p><p>I uploaded the Fusion360 source file. There are some user parameters for the most important dimensions.</p><p>You can also hit it with a heat gun and do small corrections like tilting the drivers.</p><h3>Print Settings</h3><p><strong>Material:</strong> PETG&nbsp;<br><strong>Nozzle:</strong> 0.4mm<br><strong>Layer height:</strong> max. 0.2mm<br><strong>Walls:</strong> 0.8mm (2 perimeters)<br><strong>Bottom / Top thickness:</strong> 0.8mm<br><strong>Infill:</strong> 20%<br><strong>Supports:</strong> Yes, buildplate only</p><p>Category: Audio</p>