Turtle Beach Stealth 500p Headset Repair

thingiverse

It is common for the arms to break on these particular headsets. The plastic used for the arms is ill suited. It becomes brittle and cracks. I repaired mine several times using friction welding (rotary tool with ABS filament), but they kept breaking in new places. I found a [youtube video](https://www.youtube.com/watch?v=ZMscCOSPXoo) where someone had printed a replacement part, and he was kind enough to share his model. Whilst it was a good model, it required a lot of support material (which means a lot of cleanup), and OpenSCAD would not accept it. I loaded it in meshmixer and split it into multiple parts and saved them separately. Once I had done that OpenSCAD could take the two parts and happily combine them. I took his model and modified it so that it could be printed in 2 parts (which works fine for its use case) without any slicer added support. I did have to build in some support for the arms, but I made that part of the model. I left an empty layer between the support and the arms which made them break off quite cleanly. The result worked well and seems to be much stronger than the original. Time will tell how it stands up to the punishment of a teenager...