Headphone with no-sew cushion / for 40mm driver

Hi! 

This is my partly finished headphone project. My number one design principle was a fully DIY cushion, what is washable, comfy and reparable.

For the cushion i used different type foam and t-shirt fabric with is strechy enough. 

Use “open cell” foam! The foam density highly influence the comfort and the sound quality too. I experimented with scrap piece packing material to find proper material.

The clamp hold the fabric tight to the outside of the donut shape  

The inner ring stretches the fabric and fixing the central region. The four screw poke through the fabric. The central area function as driver protection mesh.

The proper adjustments of the fabric is a little bit tricky, but with some iteration you can get a wrinkle free fabric donut.

Trim the excess material next to the clamp!

(further illustration is missing, i will make it later, check the exploded view)

Inside the main part is a nest for the 40mm driver. The drivers hold in place with a ring and 3 pc M2 screw. Around the nest are 8 venting holes. With M4 grub screws you can tune the bass response of the headphone a little blit, depend of howmany holes block or not. The bottom there is a interface plate for audio connector, you can use jack or different type of connector, on the not used side use the dummy plate. Upper side there is a cable hole and a strain relief.

Cushion with main part without driver in place.

At this stage i used salvaged headband spring steel from older broken headphone. I plan to make a printable headband. 

I found that "Open-Back" version has more friendly sound. You can make custom grill if you experimenting with grid plate in your slicer software. 

Glue it to the top cover or weld together with soldering iron as i did. 

Bill of material coming soon.

If you have a question leave a comment or send a message!