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A while ago I was wondering if it would be possible to 3D print a great sounding pair of headphones. A search online didn't throw up many other people who have done so, or any literature on how to do it, in particular making them sound great. So it was the perfect project!

After a few mediocre prototypes, a ton of testing to see how different design variables affect the sound and countless design iterations, I've arrived at a design that sounds awesome, looks great and is cheap and easy to build.

The parts should cost you around $35.

If you are interested in reading more about the work I did in creating the design, it's all at Homebrew Headphones. In particular, you can read about how the design variables affect the sound here and about my test setup here.

Step 1: Tools and Materials

Tools needed:

  • 3D printer (if you don’t have one, you can get the files printed at Shapeways or 3D Hubs)
  • Soldering iron and solder
  • Misc hand tools, eg pliers, knife, scraper etc

Materials

  • Drivers: I’ve used Dayton Audio CE38MB-32 drivers with great results.
  • Ear Cushions: Bose QuietComfort QC15 QC2 replacements, which can be bought cheaply from from Amazon or Ebay
  • Cable: Sol Republic Master Tracks HD V8 V10 V12 X3 replacements work well. Amazon and Ebay stock a variety of colours
  • Audio Jacks: 2 x 2.5mm audio jacks, such as these ones on Ebay
  • Wire: 4 pieces of approx 10cm (2″) long hookup wire with ends stripped. These from Ebay are pre-cut and stripped.
  • Glue: you need a gel consistency glue suitable for plastic, such as Loctite Gel Super Glue
  • Plasticine, Bluetac or similar. This stuff off ebay does the trick.

Files to be printed:

1 x headband

2 x baffles

2 x covers

I recommend printing them in ABS. Use 5% infill for the headband to give it flexibility, and about 10-20% for the others. The baffles and covers require support, the headband does not.

Print the parts in the orientation shown ion the photo then clean off all the raft/support.

<p>Bose mark is happy to see the acoustic engineering applied to headphones.</p><p>as 3D printed shoes, the future is near!</p>
Wow - amazing! Some serious skills there.
<p>Thanks JustBoomAudio! If you guys ever do either a mono bluetooth amp or even better, a two channel one with DSP, let me know! I'd love to a 3D printed, battery powered bluetooth speaker, in mono with a woofer and tweeter. Decent amps that are suitable for this application are hard to find...</p>
Voted cool idea!
<p>Thanks!</p>
<p>really cool! the design is simple but at the same time really nice.</p><p>you've got my vote</p>
<p>Thanks manuelmasc!</p>
These are great! The best headphones i have ever made. My attempts have been rubbish, but these have areally nice sound.
Wow they look great. Already started printing!
<p>Excellent work and that look pretty, now i want make one of this.</p><p>Congrat, i really love it.</p>
<p>They look really nice!</p>

About This Instructable

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Bio: Automotive/aerospace engineer, designer, maker, small business owner, occasional outdoors enthusiast, photography buff and travel junkie. Amongst other things.
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