This tutorial illustrates how to create a pair of functioning headphones from wood.
-an iPad with Autodesk 123D Catch software to capture my head profile (free 123D Catch download)
*you may use a digital camera & Autodesk 123D Catch for online instead
-SolidWorks CAD software to model the headphones
-Adobe Illustrator software (free Illustrator trial)
-12" x 7" x 0.85" thick walnut lumber
-1" thick high density gray foam (I purchased at Canal Rubber in NYC)
-speakers: 2X 40mm 0.1W round speaker drivers from Digikey.com, model number GF0401M-ND
-RCA jacks: 2X barrel jacks from Digikey.com, model number CP-1413-ND
-3' long 1/8" stereo to dual phono Y-cable at Radioshack
-4" of 20 gauge insulated wire
-2x brass hinges 3/4" x 11/16" at HomeDepot
-I reference my friend John's great 13:30 Printable Headphone tutorial at Thingiverse for the audio components
-ShopBot CNC router
-portable power drill or drill press
-a buddy to assist you with your 123D Catch
Step 1: 123D Catch Your Head
Using the iPad (or digital camera) open the Autodesk 123D Catch app. Have a buddy take photos of your head. Your photographer should start at a low angle & progressively increase the height of the camera. They should move around your head in about 15-20 degree increments for each photo. Use the maximum of the 30 allotted photos for a more accurate catch. Hold your pose as still as possible for the best results.
My face resulted in looking a bit warped, but my head profile was decent enough to model headphones around.
Step 2: Import Your Head Into SolidWorks
Step 3: Build Your Headphones in SolidWorks
I am not going to go into detail as to all of the necessary steps for creating the headphones, but the SolidWorks website has numerious tutorials if you need some assistance.
Create a SolidWorks drawing with all of your parts laid out how they will be cut on the CNC. Save the linework out as Illustrator files.
Step 4: Layout Linework in Illustrator
Step 5: Assign Cut Depths to Layers in PartWorks
Step 6: Cut the Parts Out With ShopBot
I was mildly successful in attempting to cut out the 2 foam earpads with the ShopBot. I compressed the foam down onto the ShopBot bed by screwing down a thin piece of plywood. I was hoping the CNC bit would cut cleaner if the foam was more dense. The inside profile came out really clean, but the outer edge of the circle resulted in being pretty rough & torn looking. After cleaning the edges up with a fabric scissors, I rather like the aesthetic though.
Wood earcups & headband:
Screw down the piece of walnut securely to the ShopBot bed. Send the linework with the top level of the earcups first, then the second layer & last the third fromt the top. Then send the the profile linework of the earcups as well as the headband.
Step 7: Finishing Work
Step 8: Solder the Drivers
Step 9: Assemble the Parts & Rock Out
Push the foam earpads onto the earcups & rock out to some sounds of WOODstock, ha.