Turtle Beach Stealth 500p Headset Repair

thingiverse

It's not uncommon for the arms on these headsets to snap under stress. The plastic used in their construction is poorly suited, becoming brittle and prone to cracking over time. I've had my fair share of repairs using friction welding with ABS filament, but new breakages always seem to appear elsewhere. I stumbled upon a YouTube video showcasing someone who created a replacement part through 3D printing, and they generously shared the model. Although it was a decent design, it required excessive support material, resulting in extensive cleanup work. Unfortunately, OpenSCAD refused to accept the entire model, so I imported it into Meshmixer and split it into multiple parts for separate saving. Once this was done, OpenSCAD was able to combine the two components without any issues. Taking inspiration from this design, I modified the model to facilitate printing in two parts, eliminating the need for slicer-generated support material. However, I did incorporate some internal support for the arms within the model itself. To ensure a clean break when the time comes, I left an empty layer between the support and the arms. The result has been impressive, offering a significant boost in strength compared to the original design. Only time will tell if this modified version can withstand the rigors of daily use by a teenager.