Overview

This is an all in one bundle of interchangeable park style headbands and ears. It brings together all three headband sizes, the full set of themed ears from the original project, multiple blank ear bases, plus some of my own custom designs. Everything is organized and renamed so it is easier to find the size and style you want in your slicer.

Print a few headbands, a stack of ears, and mix and match for any trip, outfit, or character theme.

Credits

This bundle is a remix and reorganization of the Disney Interchangeable Headband and Ears system created by Nx3CreationsLLC. 

Nx3CreationsLLC credits NINJATILL as an inspiration for their redesign and ear system, so I want to pass that credit along as well. 

Please check out and support both of their original projects.

What is included

Headbands

• Youth headband
• Adult headband
• Large adult headband

Blank ears

• Ears – Blank – No Fill
• Ears – Blank – 2.55 mm Fill
• Ears – Blank – 5 mm Fill
• Ears – Blank – Full Fill

Themed ear sets (one cleaned up version of each design)

• Toy Story Alien
• Belle
• Buzz and Woody
• Castle in Mickey
• Castle Inside Mickey Head
• Dumbo
• Hakuna Matata
• Mickey Fantasia
• Mike
• Peter Pan
• Piglet
• Pooh
• Stitch
• Sully
• Tinker Bell

Plus my own custom ear designs that will be added over time. New ear styles will continue to use the same layout and naming pattern so they drop into this system cleanly.

My changes

• Created a slightly larger headband size because the original adult band was too tight on my head
• Added four different blank ear styles so makers can build their own designs on top
• Standardized file and plate names so it is easier to find the exact headband size and ear style you want
• Collected everything into a single bundle so you only need one download for the full system

I am also actively working on multi color versions of several ear designs. Check back soon for updated files and new variations.

Design details and magnets

The original redesign by Nx3CreationsLLC focused on lighter, more comfortable ears and a no glue assembly: the ear base is integrated into the design to reduce height and weight. The ears are roughly 10 mm thick around the outer edge and about 2.5 mm thick through the inner silhouette, which helps keep them sturdy but not too heavy on the band. 

Both the headbands and ears are designed to use 3 mm x 6 mm cylindrical magnets. The magnets are intended to be a press fit in both the ear bases and the headband pockets so they usually do not need glue. If your tolerances or printer calibration make them a bit loose, a tiny drop of CA or super glue will lock them in place. 

Printing and assembly

• Print headbands flat on the bed; add a brim if your adhesion is not great
• PLA or PETG both work well
• Ears can be printed in a single color or with color changes or multi material for more detail
• Use 3 mm x 6 mm magnets in the ear bases and headband pockets
• Test fit magnets before gluing; they should press in firmly. If they do not stay put, use a very small amount of CA or super glue
• Once the magnets are installed, the ears snap into the headband pockets and can be swapped as needed

Notes

This is a fan made project inspired by Disney style park ears. It is not affiliated with or endorsed by Disney or any related brands.

Huge thanks again to Nx3CreationsLLC and NINJATILL for the original ideas and designs that made this interchangeable system possible.