Replacement Headband for Koss KPH30i

thingiverse

The headband of my Koss headphones snapped, so I made this replacement. It clamps a bit less with my filament and ditches the size adjustment. The .stl fits MY head, that is very big - nearly maximum of the original size adjustment. # Assembly * Print with recommended settings * Cut the drivers from the original headband as seen in the picture * Transfer the silicone headband from the original to the replacement * Insert the drivers into the slots, check fit and clamp on your head, glue them in # Customizing for your head size Don't scale the .stl in the slicer! The silicone headband won't fit anymore. **My head is bigger!** Super easy: Just don't insert the original parts into the slots completly and glue them as needed. **My head is smaller!** Shorten the slot length of the 3D-print and the headband stub of the drivers. You can easily shorten the slot length in the Fusion360 source file as well. **Other customizations** e.g. headband thickness (clamping force), clearance in the slot, position of the silicone headband... I uploaded the Fusion360 source file. There are some user parameters for the most important dimensions. You can also hit it with a heat gun and do small corrections like tilting the drivers. # Print Settings **Material:** PETG **Nozzle:** 0.4mm **Layer height:** max. 0.2mm **Walls:** 0.8mm (2 perimeters) **Bottom / Top thickness:** 0.8mm **Infill:** 20% **Supports:** Yes, buildplate only