Tofty Headphones 6: "Easy Print"

thingiverse

I present my attempt at an easy to print pair of headphones. These were designed to use few non-3D printed parts and for those parts to be easily sourced from ebay, aliexpress, etc. There are several different configurations these headphones can be built with: There are two different types of 3.5mm audio jack panel mount connectors that can be installed into the ear cups. One screws into the earcup from the outside, while the other passes through a hole from the inside and is retained using a nut on the outside. Different versions of the earcups exist for these two connectors. There are also versions of the earcups which either have one or two jack connectors on each side, depending on whether you wish to use a bridge cable or not. TH6 Cup 02 - External jack connector X2, TH6 Cup 03 - External jack connector X1, TH6 Cup 04 - Internal jack connector X1, TH6 Cup 05 - Internal jack connector X2. Check the Solidworks or .STEP files for a 3D models of both types of jack connector, to ensure you're ordering the right connector for the desired arrangement. The external jack will require the holes being tapped with an M8 x 0.75mm thread. For the Forks; the 01 version doesn't have the mounting holes for the cable clips, while 02 does, so only the o2 version is suitable for use with the bridge cable arrangement. While I'm using a clear Acrylic disk in the back of my ear cups, there are a few other printable options included: A vented open back panel, A closed back panel, A thinner closed back panel that allows a 0.5mm wood veneer sheet to be installed behind it, for a more attractive appearance. Parts Required (other than printed parts): 4x Aluminium M3 x 55mm round standoffs, 5mm diameter (ebay, various other lengths and colours are available), 8 x M5 1mm thick nylon washers (ebay) 1x Beyerdynamic DT770/990 headpad (copies can be found cheaply on ebay), 2x 50mm dynamic drivers (the Peerless by Tymphony HPD-50N25PR00-32-ND drivers are what this model was designed for and can currently be found on Digikey) 2x 105mm ear pads (probably worth getting a few different types and seeing how much they change the sound), 2x 70mm diameter x 2mm thick clear acrylic disks (ebay, can be substituted for various other options), 2x or 4x 3.5mm 3 pole audio jack panel mount connectors, either internal or external mount (ebay), 1x right angle 3.5mm jack TRS (3 Pole) 1 metre audio cable (ebay, the extra length of the cable can be hidden on the headpad) Fixings: 58x M3 x 10mm Countersunk Hex A2 screws (used almost everywhere) 4x M3 x 18mm Countersunk Hex A2 screws (used on the Fork Pins) 4x M3 x 6mm Grub/Set Hex A2 screws (used to prevent rotation of the externally mounting jack connectors) 4x m4 x 6mm Grub/Set screw nylon or nylon tipped (used to add resistance to the Ali standoffs in the headband). All holes should be drilled and tapped for the correct thread. Tools Needed: Small hand drill, 2.5mm drill bit (tapping drill size for m3 x 0.5 threaded holes), 3mm drill bit (for all non threaded holes for the m3 screws), 3.2/3.3mm drill bit (tapping drill size for m4 x 0.7 threaded hole), 5/5.1mm drill bit (widening the headband holes for the ali standoffs), 5.3mm drill bit (for the fork pin holes on the forks), 6mm drill bit (for the hole that the internal jack connector passes through) 7.3mm drill bit (tapping drill size for m8 x 0.75 threaded holes), Small countersink bit (for all countersunk holes to clean them up and deepen if required), M3 x 0.5 tap (for almost all holes) M4 x 0.7 tap (for the 4 side holes in the headband) M8 x 0.75 tap (for the externally mounting jack connectors) Remixes are encouraged. Please share any ideas you may have on this project with the community; by using the REMIX button on your upload. These CAD files were created with Solidworks. There are both Solidworks and .STEP files included, along with the .STL files, to aid in making modifications. I hope you find my work of interest.