Tofty Headband 1

I present my attempt at a DIY headband for a pair of headphones, that can be made using just 3D printed parts and easily available materials.

The main structure of the headband is made from 3mm rod, cut to length.
This can be made from many materials, but I would recommend 303 Stainless Steel, Grade 5 Titanium or Carbon Fibre, as they are all suitably springy. This current design uses just under a metre of rod in total. If the band ends up flexing too much I might consider adding one or possibly two more rods to the middle span, to stiffen that area up have most of the flexing occur at the sides.

The printed plastic parts take almost no load when the headband is being worn, as the rods rest on each other. They just hold the rods in place using UNC 4-40 x 1/8" grub/set screws (M3x3mm screws would also work, but I prefer the courser thread of the imperial screws).

The headband is a slight remix of "GiraffeMetropolis' Audeze LCD Headphone Strap" and should be printed using TPU f