Improved Koss KPH40 headband repair

STEP and Fusion project files are included. You can change it any way you want. Yes, one side is slightly shorter. That's to make it bend naturally!

Make

I printed on Prusa Mini with 0.25mm nozzle and 0.07mm layer height, 100% infill with Devil Design PLA.

Parts and supplies needed

For one side:

3x M1.7 self tapping 3mm countersunk screw with flat bottom. Like the ones found in plastic housings.

2x printed parts. You need outside and inside.

Both parts are in one file, some slicers ask if it is one object of multiple parts. Press no)

How to

print parts

put first screw in inside part

press outside against headband

put the headband and inside part together with the outside part

screw in the first screw but don't fully tighten (this is a little hard sometimes)

screw in the other screws, again don't fully tighten

slowly and carefully tighten the screws, don't overdo it because you will strip out the plastic

adjust to your liking, tighter means harder to change headband position.