Fiio FT1 Hinge Replacement

I love these headphones, but my big head keeps breaking the hinge area that holds the head band to the arms that hold the cans. Thankfully as I have found out, because Fiio has opted to just have the cans feed directly into a cable instead of wrapping through the headband, these are also very repair friendly. So I spent a weekend reverse engineering the hinge area to beef it up and hopefully fix a few of the fail points in the original part. Certain areas are thickened up compared to the original part, which is very svelte and thin. I did introduce some chamfers to the shape to have a nicer hand to it and not have it just be a gigantic sharp edge block.

I'm still relatively new to designing things in CAD and respecting tolerances, so the fit is a little tight in areas but you won't need to force anything with unfathomable strength. If you feel too much resistance, double back and check to make sure the parts are fitting together correctly. The headband will probably need to be seated