Headset Cushion

This is a delicate model to print due to the hollow form. I have printed it many times successfully so please read on before printing

My old Logitech Headset cushions worn out and started hurting my ears. The replacement pair I ended up ordering online were too small and didn't work, then I remembered I have a 3D printer and designed my own.

I Couldn't be happier with the results and I hope this will come handy for your too. This must be printed using a flexible filament like TPU. It will print great in PLA but you'll have a hard time putting in on and it feels wired on the ears (I actually tried it) so use Flexible Filaments.

There are two profiles:

• Minimal support: You'll end up with no to minimum support. There will be some stringing because of overhang but the results should work very well.
• Normal Support: Not much stringing and the result look good but removing TPU support is not fun.

I recommend trying the Minimal support version first and only try the support version if that didn't work.

This is a parameteric design. So if the size I have didn't meet your needs then please rescale in your slicer or just leave a comment with the following measurements and I would try to add a profile for you (unless I get overwhelmed with demand - famous last words - not gonna happen).

1. The size of the hole you need on the back of the cushion (this should wrap around the back of you head-set's driver (mine was 40mm). you will need a size larger than the foam cushions to make sure they can fit easily.
2. The Major Axis (longest axis of the oval) of your existing headset cushions. Mine was 75 mm
3. The Minor Axis (shorter axis of the oval) of your existing headset cushions. Mine was 65 mm
4. The overall thickness of the cushion front to back. Mine was 8mm. This needs to be thick enough to fix your headset driver but not too tick to go loose.

Please see the image below for an example:

You are more than welcome to Remix this model but I'll ask you to please consider giving me a boost if you are remixing or if this model generally helped you.