DIY Headphones
![DIY Headphones](/content/images/size/w2000/2021/12/20201225_111607-1.jpg)
A lesson in prototyping.
The problem: my friend does not like earbuds because they fall out. And does not like headphones because they are too hot and put too much pressure on his head.
My plan: make a hybrid earbud/headphone taking design cues from old walkman headphones.
First I designed some different cups for the earbuds and 3d printed those to test.
Five iterations:
![](https://julianna.digital/content/images/2021/12/20201224_221510.jpg)
![](https://julianna.digital/content/images/2021/12/20201224_221501.jpg)
![](https://julianna.digital/content/images/2021/12/20201224_221535.jpg)
Then I soldered a sacrificial pair of drivers and seated them in the new cups:
![](https://julianna.digital/content/images/2021/12/20201224_224137.jpg)
The earbud cups are then attached with zip ties to a very lightly clamping frame. This allows them to be adjusted up and down to the size of the wearers head.
The final product:
![](https://julianna.digital/content/images/2021/12/20201225_111607.jpg)
My friend was very happy with the final result and it made a perfect Christmas present!