Taotronics BH040 Headband Replacement Brace

thingiverse

I originally designed a <a href="https://www.thingiverse.com/thing:4593626"><b> repair brace</b></a> to fix fracture damage to the headband of the <b>Taotronics BH040</b> headphone model. Alas, after about a year and a half of using those, the rest of the headband failed completely due to the formation of micro-fractures underneath the braces themselves. That is to say, the two side parts of the headband shattered into smaller pieces and could no longer be fixed due to loss of integrity on the part. I thus decided to throw together this replacement part based on the original part's measurements. (As a user pointed out previously that the older repair clamps also seem to work on the <b>BH060</b> headband, it's possible these proportions carry throughout multiple Taotronics models. Would need further confirmation to see if this part works on other models than BH040.) In summary, these headphone models have a particular under-designing flaw: they use small M2 screws to fasten together the headband components at the terminal ends of their plating, which doesn't provide nearly enough resistance to negotiate the stress from daily usage. Thus, my replacement part has been beefed up with these following considerations: - 6 M3 screws instead of 4 M2 screws to provide more adequate fastening strength along the full length of the part. - Screwsholes are aligned on the outside of the frame as drilling holes closer to the middle would create a weakness between the 2 holes. - Tighter ratcheting mechanism for a stronger clamp on the extending part of the headband. - Pivot mechanism is preserved: plastic detent could use more tightening, but I am satisfied that the headphones are able to fold up properly in this configuration. I'm releasing this in case anyone else finds themselves in the same boat, along with reference stl models of the measurements I've taken in the creation of this part. At this point though, let's be honest: if like me, you have a big/square head, this is but a temporary salvage measure. But, with a bit of patience, it may just buy us enough time to save up for a sturdier pair of headphones. <hr> # HARDWARE - (6) 8mm M3 Screws (per brace) - (6) M3 Hex Nuts (per brace) <hr> Print at 80% infill and above for optimal strength. I would go so far as to use PETG/ABS instead of PLA as the latter is brittle and has a tendency to fissure under continual stress. Print as is in the provided orientation, so that the grain of the plastic goes along the length of the parts.