SONY MDR-XB950BT Swivel Brace

thingiverse

This is a brace/splint to repair a broken headphone cup swivel for the SONY MDR-XB950BT model. The swivel design on these headphones is very thin and prone to breakage. After multiple instances of gluing them and having them break again, I designed this brace to use screws and threaded inserts to maintain the ear cup attached to the headband. Additionally, I used dual lock reclosable velcro from 3M to connect each of the two long 'arms' of the 'Outside' piece to the bottom-most part of the swivel (see pictures). This reduces the amount of load experienced by the swivel when grabbing the ear cups to either put the headphones on or take them off. The downside of this design is the removed ability for the ear cups to rotate, although this has not been an issue for me in terms of product storage or comfort during use. The 'Outside' piece has countersunk holes for screws of 82 Degree Countersink Angle, 10-32 Thread Size, and 3/8" length (https://www.mcmaster.com/92210A301/) The 'Inside' piece has holes to mount the corresponding heat-set threaded inserts (https://www.mcmaster.com/94459A350/). Make sure to attach the inserts to the piece from the side closest to the screws. Disclaimer: The dimensions were slightly adjusted so that the brace fit over leftover pieces of glue still stuck to the swivel from my previous attempts to fix it that way. Feel free to remix this design to accommodate your own headphones or feel free to reach out and I can make adjustments to help you test.