Sony WH-1000XM2 Headband Fix Hinge

thingiverse

After almost 4 years of use, the headband on my WH-1000XM2 started cracking next to the hinge. This seems to be a common problem on Sony's high-end headphones. Such a shame! I tried to glue it with epoxy resin, which obviously did not prove to be a good solution. So instead I decided to design a clamp which can be easily printed - compared to a replacement part - that has a tight fit around the cracked parts. I printed it standing up on the "not-so-much-angled" side at 150 micron resolution using PLA. To mount it, you have to full extend one earcup and press fit it above the exposed slider to push it onto the broken part from the top towards the earcup. Unfortunately, near to earcups, Sony's design get a little wider, such that you can't slide it on from the front. For the uploaded model, I corrected the angle near to the twist mechanism of the earcup in order to get better asthetics, the pictures show an older version.