Replacement Headband for Koss KPH30i

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

Category: Audio