Story: After many years of solid service, knocks and tumbles, it had finally happened. A mistaken move, and a tumble to top any drop. The outer earphone hinge had cracked and is pining for the fjords. It had ceased to be...

As I stooped down and cradled my headset, earphone limply swaying from my trembling grasp, I thought, well this is the end of an era... I guess I'll have to buy a new o---ooh wait! 3d printers are a thing! I have that thing!

So off I went to the drawing board, or so to speak.

Inspiration/Reference This design used the original outer shell as a reference. I was inspired/motivated to throw myself at the problem for a while after discovering an Inner Hinge cover design by Ittook36versionstomakethis (which I also needed for my headset).

This is not a perfect match mind you, the casting they did on the original makes it rather difficult to reproduce the curvature. I have definitely worn my calipers down trying to get something similar in dimension but I believe I have something that is quite functional and similar in profile to the original.

Design choices I decided to leverage this outer shell as the brace/mount for the earphone pivot pin. Observing how the headset band and earphones flex when wearing, having the channel bracing the pivot, the solid outer shell should provide more rigidity and resistance to flex. The idea being that the Inner Hinge cover essentially just sandwiches the pivot against the Outer shell.

Model Revision Details

Revision 9

• Move bottom left screw-mount up by 0.25mm
• Add support braces to screw mounts to help with overhang printing and base strength
• Increase Swivel Pivot mount height to tighten clearance between mount and driver
• Simplification of STL mesh to reduce file size

Resolution/Fit Recommend printing at a resolution between 0.1 and 0.2. If using larger resolutions, the fit may be rough and bit snug at a 0.3/0.4 resolution, so you may have to coax the screw mounts through the headband holes. See Post-Printing for general application directions

Recommended Companion Part

• My Remix - I have had best results so far with my remix of ittook36versionstomakethis' part. This remix has a flush brace surface on the back side of the Inner Hinge, which provides more surface area for the headphone pivot pin to brace against.
• Inner Hinge made by Ittook36versionstomakethis will work, you just have to snap off the two protruding braces.

PART NOTES:

• The part uploaded is for the Right side headphone.
• Flip/mirror STL on the Axis that the pins run parallel to, in your slicer to get the Left side :)