Tunable "Open/Closed" Headphones

thingiverse

This design draws inspiration from classic 60's and 70's headphones made by Lenco in Switzerland. Fed up with headphones that are designed to fail after a short time, I set out to create something more durable, where any part can be easily replaced quickly. Print Settings Printer Brand: Printrbot Printer: Printrbot Simple Metal Rafts: No Supports: Yes Resolution: 0.2mm Infill: 20% Notes: Disable small gap-fill for all printed parts and use three perimeters. Open Earcups: Print the earcups with the open end facing down, add supports up to the "socket" at the back of the cup. Closed Earcups: Print the earcups with a large open end facing down, print the back plate logo side down. Arms: The print settings should allow for a small 0.2mm gap in the middle of the arm structure, which is for the "flex". You will also need to fill the bolt-slots in the slotted upper-arms with supports. Front Baffle: Adjust the baffle to fit your speakers/drivers. Design and print adapter rings with an outer diameter of 42mm on which to place your driver, so the diaphragm is clear of the grill. Your adapter ring should have an inner diameter equal to your driver's outer diameter plus 0.25mm, and an outer diameter of exactly 42mm. Post-Printing Assembly Start with the upper/slotted arm and earcup arm using a 4mm screw, washers, and locknut. Repeat for attaching the arms to the earcup. Then use a bolt and locknut to attach the headband to the upper arms. Insert wiring, glue the driver to the front baffle, solder cables to drivers, remembering to run the wire through the correct holes. Also leave some play on the wire that goes from left to right earcup. Cushions: Use standard AKG earcup cushions which are roughly 100mm across. K240 or K271 compatible ones work well. I liberated the headband cushion from an old pair of Shure headphones for the headband. There are "generic" ones on eBay that button up over the headband also. Sound Tuning: The front baffles come in two versions, vented and closed, with the vented one being tunable to reduce bass. Cover vents one by one to increase bass as desired. Also experiment with material between the baffle and the ear, like felt or sponge. see: http://www.brentbutterworth.com/headphone-voicing.html