UGREEN HiTune Max3 Headband Replacement

This is as close to the real stock headband as I could model in Fusion 360. The padded part clips onto it just like on the stock headband, and the adjustable earcup mounts also work fine. You just transfer all the hardware and the tape that lets them slide smoothly there.

I don't own a pair of these headphones, so I probably won't be making additional fixes to these unless they are really simple and don't need to be tested, but I am uploading the source files, so feel free to change anything you need.

Printing considerations:

Material

Due to the printing orientation, the actual teeth of the latching clips can break off pretty easily along the layer lines, so use a filament with good layer adhesion. I used Prusament matte black PETG for my final part, and the layer adhesion was a lot weaker than on the generic PETG I used for test prints, so keep that in mind.

This also needs to flex for a long time without permanently deforming, so don't print it from PLA. PETG should be fine, though it might still creep a bit over time.

Support

This needs a ton of supports, and there are a few ways you can go about this:

• Use tree supports for easy removal, but the lower clips will not come out great

• Use normal supports, but removal will be much harder

The one in my photos was printed in PETG with PLA supports, which do not stick to each other, but removal still took an hour, and on my first attempt, I tore off one of the small screw bosses, so I had to reprint again.

If you can, use soluble supports for this.