I bought myself the Sony WH-XB900N headphones. For those that don't know, this is Sony's mid-range line of headphones. They look like and in fact use the exact same shell as the more popular WH-1000XM3 flagship headphones, but apparently with less good features? Anyway, that part is not relevant, this is not an ad.

Recently, I bought my girlfriend the Sony WH-1000XM4 headphones, because she deserves the best things. That pair comes in a neat travel case, while mine came in just a thin canvas bag, which I naturally became jealous of. But, of course, I can make stuff, so I made this case!

Compatibility

It just so happens that industrial designers are sometimes not the most creative bunch, and A LOT of headphones are the same size. Here are some headphones that I know will fit in this case (sorry for the long list, but this will hopefully both be useful for you and for SEO):

• Sony WH-1000XM4
• Sony WH-1000XM3
• Sony WH-1000XM2
• Sony WH-XB910N
• Sony WH-XB900N
• Sony MDR1000X
• Bose QuietComfort (QC) 45
• Bose QC 35
• Bose QC 25

Most other “foldable headphones” (awful name, because it actually describes the way they fold, and is different from, for example, “flat rotated headphones”) will fit. Manufacturers like TaoTronic and Infurture make Bose clones that will of course also fit in this case.

Print settings

You will need to print one of each part. These are the settings I recommend to get a very sturdy vase mode case (that's right, vase mode but strong and up for the job of protecting your headphones when you find yourself needing to sit on your bag in order to close it):

• Spiral vase mode / Spiralize outer contour: turn this on, that's what this mode is all about
• Line width / Extrusion width: 0.8mm (you can do this even with a 0.4mm nozzle)
• Bottom thickness / Bottom layers: 1.5mm
  • Bottom pattern initial layer: concentric (this is optional, and not all slicers support it, but I think it looks better for display pieces… but use your own judgment)
• Speed: 60mm/s (this value almost doesn't matter, since it won't actually be used)
  • Wall speed: 30mm/s (unless you are super sure your extruder can keep up with faster)
• Ironing: enable this for a better inside finish (protip: Cura has better ironing support for vase mode prints from what I can tell)
  • Ironing Line Spacing: 0.4mm
  • Ironing Speed: 40mm/s

Special note for PrusaSlicer and other Slic3r derivatives: Under Print Settings > Advanced, there is a "Slice gap closing radius" setting. You need to set this to 0. This is very important.

Notes

The prints in the photos were printed on an Elegoo Neptune 2 with a 0.4mm nozzle in Tianse woodfill PLA.

For other boxes and containers I have made in the same style, check out this collection.