Sony WHXB900N Headphone Fix

Clamp to repair headphones that have split between the panel on the headband attached to the cup, and the slider. When you pull these headphones apart to put them on your head, especially if the sliders are slid down very much, it puts a lot of strain against the plastic shell. 

Oriented with the lower angle on the bed, this print seems significantly stronger than original. The gap is wide enough to allow the ear cups to still fold up. 

I did originally try making this in two pieces, to be fit around and screwed together, but this is working well and is easier to print. 

I also tried with a 90deg end at the top, but that led to a significant overhang. As uploaded, it is easy to print, but doesn't perfectly cover the arm. 

Recommend printing with the lower angle on the bed, with a brim. 

Installation - Snap the original parts back together, fold up the ear cup, and slide the printed part on over the broken section. This part is designed pretty tight, so if you have any amount of over extrusion, it may not fit. A small file to smooth out the ridges helped a lot, and to smooth out the entry to the part. The headphones are reasonably tough, so you can push pretty hard on them, but if it's not going on or coming off, you may need to cut off the printed part and try again. 

It appears this would also work on the Sony WH-XB910N headphones. The WH-1000XM3, XM4, and XM5 switched to a different band style. See this model for XM3 repair.

You could also add a mid plane on the outside and make ears or other decorative features, but I needed to get these done in a hurry for a meeting. Feel free to remix or let me know if you're interested and I might be able to help.