Replacement Ear Cushions for Sony WH-XB700 Bluetooth Headphones

General Info

The Parts are symmetric and can therefore be used for both the left and right side.

In Addition to the cushion piece a spacer piece is also included with the Model. These are optional and not part of the original. They are meant to help with Clearnce issues with some geometry sticking out from the speaker module of the headphones.

Print Instructions

Cushion Piece

The cushion Pieces must be printed from a FLEX material.

1. Use the assembly (replacement-ear-cushion-asm) version of the step/stl file. (already includes the net part at the correct position)
   • NOTE: The STEP file references the external files "ear-cushion.STEP" and “net.STEP”, wich are required to be saved in the same folder.
2. Use part modifiers to print the net part with the following settings.
   • Infill - Density: 40%
   • Infill - Type: Gyroid
   • Bottom Solid Layers: 0
   • Perimeters: 0
   • Top Solid Layers: 0
3. The print settings of the main part depend heavily on the material used, as well as the preferred stiffness.

Example settings using ColorFab VarioShore TPU:

• Infill - Density: 5%
• Infill - Type: Gyroid
• Bottom Solid Layers: 7
• Perimeters: 1
• Top Solid Layers: 3
• Print Temperature: 250°C
• Print Speeds are in the range of 10 to 20 mm/s

Slicing of ear-cushion.

Spacer Piece (Optional)

The Spacer Piece can be printed with standard materials (PLA/PETG).

Replacing the Parts

1. Pull off the original damaged ear cushion, wich are simply glued on.
   
   
   Headphones with damaged and worn out cusions.
    
2.  Remove Adhesive residue:
   1. Remove the majority with a plastic scraper.
   2. Remove the rest using paper towels an IPA.
      
      
      Headphones with ear cushions removed.
       
3. OPTIONAL: Mount the spacer piece using double sided tape.
   
   
   Headphones with optional spacer pieces mounted.
    
4. Mount the cushion Piece using double sided tape.
   
   
   Headphones with ear cushions mounted.

Cost Estimate

• Material cost for one ear cushion when Printed from VarioShore TPU: 1,65 € (~ 1,77 $)
• Material cost for spacer piece when printed with PRUSAMENT PLA: 0,45 € (~ 0,48 $)

Therefore, both ear cushions (incl. spacer) can be replaced for a total cost of 4,20 € (~ 5,51 $)