Summary

I was really frustrated when my 250$ headphones broke because of factory fault. Cost of their repair in Microsoft is approximately 200$ and they refused to send just this part so i recreated this in Fusion360. I've not printed this yet so can't upload photos. As fast as i print this i will upload photo ;) I hope this will help many people to fix their headphones.

UPDATE(added step file from f360 for those who asks)

UPDATE (v3 - v2 was skipped):

• better hinge fitment - each screws mount was moved 0.5mm to middle
• wider cable holder

Compared to original:

• it's aprox. 1mm thicker
• it has a little bit wider angle
• even if you print this with PLA it will be much stronger than original, cuz PLA is more flexible ;) I also recommend printing this using PLA, cuz it is the easiest material to work with.

Conclusion:
It needs a bit sanding in the end, but fits perfectly. I highly recommend to print this with tree support instead of usual one. I printed it in white color and in the end sanded it and painted with space gray acrylic paint. If skeleton (black part) under headband crack while disassembling just glue it with superglue, and then snap in place. I've personally glued even rubber bottom to printed part as it was good idea for better fitment ;)

UPDATE (after one year of using it daily):

• I've uploaded also photo of painted headband (the one with earmuffs covers).
• It is still strong and nothing bad happens with it.
• PLA was good choice to print.

If you liked this design, it helped you or if you want to support this work, you can buy me a coffee or make a tip through links on my profile.

Print Settings

Printer Brand: 

Creality

Printer:                      

Ender 3 Pro

Rafts: 

No

Supports:                      

Yes

Resolution: 

200

Infill:                      

20%-50%

Filament: 3D Active PLA Gray                    
                        

Notes:                     

Highly recommend to print this with tree support option.