Sony XM5 Qi Charging Ear Covers & Stand

Addons for Sony XM5 headphones to enable wireless Qi charging.
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updated January 23, 2024

Description

PDF

This design places a Qi receiver inside of a 3d printed cover for the right earphone. Note that this prevents access to the touch controls. A matching left ear cover can be provided to make the two sides match. The headphones charge by placing them in a matching stand/dock with a Qi charger.

Non-Printed Parts

Instructions:

  • 3D print one of each STL:
    • headphone-left-cover / headphone-right-cover
      • Print in PETG or PLA. Needs to be a semi-rigid plastic.
      • Print in the orientation shown in the pictures with support enforcers.
      • Use 0.2mm layers with adaptive smaller layers near the top.
      • Note: You can get a better surface finish if you print with the large flat surface on the print bed but this will require either adding supports for the protruding tabs or removing the tabs and using tape to attach the covers to the headphones.
    • stand-body / stand-charger-addon
      • Any settings. 10% infill
    • usb-bottom / usb-top
      • PETG. 0.2mm layers. 100% infill.
  • Assemble the Qi Receiver wiring
    • De-solder any wires already attached to the Qi receiver board.
    • Place the Qi receiver coil and board into the headphone-right-cover to verify it fits and measure out enough wire to reach from the board to ~1cm outside of the USB port hole.
      • ~26 AWG stranded wire should be ok for this.
    • Solder the wire to the Qi charger and USB-C breakout board (matching + to +, - to -)
      •  
    • Insert the USB-C breakout board into the usb-bottom part, insert a bunch of hot glue on top of it and then place the usb-top part on top (will stick together using the hot glue)
  • Use double sided tap to mount the Qi charger inside of the headphone-right-cover
    • Leave the USB-C connector dangling outside of the cover with the wires going through the open hole at the bottom.
  • Attach both covers to your headphones.
    • Now is the time to plug in the USB-C plug:
    • (in the above photo, the left cover is using variable layer heights and the right one is using uniform 0.2mm layer heights). 
  • Mount the Qi charger module in the stand-charger-addon part
    • Do a fit check first before sticking anything down. You may need to extend the wires to make it reach. 
    • The coil should have adhesive tape pre-installed that you can use.
    • Fix the board in place with hot glue
  • Insert the heatset inserts into the 6 holes in the stand-body
  • Connect the two stand parts together using the M3 screws
  • Done!

Model origin

The author marked this model as their own original creation.

License