This project is still a work in progress so files are not published. I am currently working on version four of the design. These are designed to be entirely 3D printed with the exception of electronics, fasteners, and cushions. This introduced many issues because of the tradeoff between strength and bulk that aren't as present when designing headphones with metal components. Another issue that I had to work around was the anisotropic properties of 3D printed parts due to layer adhesion and the limits of overhangs when printing. I needed to design parts with directional strength in mind as well as the limited printing orientations. For material, I settled on using PETG because of its good layer adhesion and elasticity which are good properties for printing in general as well as making a functional headband. 

Version 4:

I resolved many of my prior issues with version four, but there are still a few problems. The headband arclength is still a little short so when wearing the headphones I need the adjustment slides to be fully extended. Another issue is with the ratchet for the slides. The tolerance isn't quite right so there is some play. At moment, the design works for everyday use, so I haven't put much more work into it since I printed it in 2020. After a year, it is still in one piece which means my attention to stress concentration this time around has made a huge difference.