Sennheiser HD280耳罩模型
Sennheiser HD280 Earcup
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Summary
Much like an underwhelming recipe, a story must come before the ingredients.
I have a pair of Sennheiser HD280s. I love them, great audio for the price with a solid and simple construction. I especially like that they're pretty simple. A pair of drivers with a quarter inch cable. HOWEVER, the included earcups are made of this thin plastic like stuff that flakes off and dies after about a year of use. Now, higher quality replacements come cheap and seem quite comfy, but I have a spool of TPU and a hobby account for OnShape.
I designed a V1, which I am currently wearing on my right but not left ear. It kinda sucks, but it keeps my ear (mostly) off of the hard plastic. I'm currently printing a V2, which I have uploaded here.
I also made the OnShape document mostly parametric, so if your headphones have an elliptical shape then you should be able to adjust the parameters to make these work.
How I Designed This
Design Principles / Reasoning
There are two obstacles when designing these that I encountered. Attaching the cups, and making them comfortable.
For my purposes, I wanted attachment to be possible without any extra hardware or modification of the headphones. The original cups used a silicone-like ring that would stretch and fit into a slot around the outside of the headphones. This held the cups in place EXTREMELY well, but were a pain to remove and reinstall. Even if I did want this design, it would be impossible with TPU, since it really hates overhangs. I figured a straight wall that kinda stretches around the outside of the headphone would work, and it did. The layer lines and the stretch of the plastic keep the cups on well enough that I haven't had them fall off yet, and attaching is easy as pi.
For comfort, I wanted something that would form to my head. TPU fits this job perfectly, and I had a roll of the less stretchy stuff sitting around that would do the job nicely. TPU is also safe against skin for long periods of contact and should be pretty hardy to nasty face oils and sweat. The V1 that I'm wearing now was printed with 8 bottom layers, which doesn't give nearly enough to form to the head. More on that later. Temperature might become a problem, but I can add vents if it is.
Printing
Print settings
To start, I encourage printing this with TPU. I'm designing this around 95, since that's what I have, but I think more squishy would be more better in this case.
Specific line size and whatnot probably won't matter for this.
I recommend 2 bottoms, 2 walls, 5% Gyroid, and 8 tops (talk about a fun night wuhhey)
More that 2 bottoms and higher than 5% Gyroid will probably make the cups too squishy
No post-processing should be needed, besides removing a brim if one is used
Please give feedback, I love improving my designs.
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