Drop THX Panda Headphone Reinforcement Fix
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My Drop THX Panda Headphones started to break at the headband hinge so I designed and printed this small clip to fix it.
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I love my Drop THX Panda headphones but the headband hinge that allows the cups to swivel has always been a weak point. Lately it has almost completely broken, allowing the right cup to tilt and swivel past its stops. They still work fine, but I fear they are on the verge of breaking past the point of functionality.
I designed this clip to fit around the hinge to reinforce it. Originally it was designed with an inner and outer clip to hold itself in place without any fasteners or glue, but I ended up using only the inner clip and some fabric tape to hold it in place. Your mileage may vary.
One downside of this design/fix is that you lose some adjustability of the headband, so the headphones may no longer fit smaller heads. I have an average size head for an American male and I have to use the headphones on one or two steps above the smallest remaining adjustment available.
You will also find a .STEP file of my rudimentary model of the headband hinge assembly if you would like to create your own clip. Please let me know if you improve upon the design!
After loading the .STEP file into your slicer, right-click the part and Split to objects so that they print individually. I printed mine in PETG at 0.15mm layer heights with 10 perimeters/walls to create a completely solid part. Have had them on the headphones for months without any issue.