Speaker or headphone main components:
The three main components of any speaker is a diaphragm, voice coil and the magnet. The magnet helps produce the music by creating the magnetic field so the voice coil can vibrate. The voice coil is in a speaker so it can create a second magnetic which in cause helps it vibrating so it can vibrate the diaphragm, so it is better to have more coils for better vibrations. The diaphragm is part of the speaker so that it can vibrate which sends the vibrations through the air to someone's ear.
In my process of creating and testing the voice coils, I found that the more coils that one has the better the quality of sound because there is more voice coils the strength in the magnetic field, and, in turn, make the vibrations stronger
We experimented with the number of coils test 10, 20 and 30 coils and found the quality and loudness of the speaker was better with more coils. This is because the more coils the stronger the magnetic field making the vibrations stronger.
With the vibrations from the voice coil and diaphragm turn into the waves once in the air.
After finalizing the design of these headphones I was able to hear the music loudly, but the louder the headphones get they get a little fuzzy in sound quality.
Step 1: Gatering Materials
9ft 28 gauge copper wire
4 plastic cup (2 larger than the others)
old headphones or headband
4 large rubber bands
thin cloth (I used an old tee-shirt)
2 neodymium magnets (the stronger the better)
2ft wire tubing (optional)
Step 2: Create Voice Coil
Materials used in this step: copper wire, glue stick, wire cutters electrical tape, sand paper.
1. Measure 3 feet of wire and cut using the wire cutters.
2. Cut a small piece of electrical tape, wrap around one end of glue stick upside down (so you can easily slide voice coil off of glue stick).
3. With the wire hold one end at the end of the tape on gluestick, and wrap around with no gaps, and no overlapping till you reach the end of wire.
4. Carefully tack voice coil off of glue stick, and at each end of coil tack one inch of wire out so it looks like this -0- now you can tape it together to secure it.
5. Now sand the wire sticking out of the coil, so there is no red showing. ( for later connections)
Step 3: Preparing Cups
Materials used in this step: scissors, cups, aluminum foil.
1. On the two smaller cups tape the aluminum foil over the top of the cup (this amplifies the sound)
2. On the two bigger cups make a cut on the side of it so you can attach to the headband.
Step 4: Putting Speakers Together
Materials used in this step: smaller cups voice coil magnets.
1. Place the voice coil on the bottom of the cup with the magnet in the middle.
2. Tape over the bottom of cup multiple times so it stays in place, (don't tape the ends of the voice coil).
3. Repeat on the second cup.
Step 5: Add Wire for Connections
Materials used in this step: copper wire, wire cutters
NOTE: ALL WIRE ENDS MUST BE SANDED
1. From one of the voice coil ends, twist together with 10in of wire, does the same for the other end with another voice coil.
2. Now get 1.5ft of wire and attach to other voice coil end. (Do this once for each coil, let other ends of 1.5ft wire dangle for now).
Step 6: Aux Plug Connection
Materials used in this step: aux plug, sand paper.
1. Sand ends of dangling wires.
2. With one wire twist over part of aux plug so it is connected firmly, tape over all bare wire for this wire.
3. On the other wire tape to another part of aux plug, no need for tape.
Step 7: Assemble
Materials used in this step: Electrical tape, headphones, headband.
1. Tape the smaller cup to the larger one.
2. Secure the cup to the headband via whole on the side of the cup, then tape to secure.
3. Tape the wire connecting the two speakers to the headband.
Step 8: Tape Over Wire (for Looks)
Materials used in this step: electrical tape, assembled headphones.
1. Tape over all wire that is showing so it looks better.
Step 9: Add Cover
Materials used in this step: Cloth, electrical tape, headset, rubber bands.
1. Cut the cloth into 2 circles slightly bigger that your larger cup.
2. Place over cups and add rubber bands to the cup so they stay there.
3. Cover the bottom neatly with electrical tape so you don't see the cup.
Step 10: Test and Troubleshooting
Probably on your first test, it won't work perfectly but test it anyway. (Use a computer, at first, they have louder sound). If it doesn't work that time here is some problems that can occur.
1. Wire connections are not strong enough. In this case, twist the wires tighter and sand them more.
2. The bare wires at the aux plug are touching, they can't touch to work.
3. Let me know if you run into any other problems, and I can try to find a solution.