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.