Corsair HS80 / HS80 Max Hinge Buckle Repair

This component is a small plastic hinge buckle plate that fits at the headband-to-earcup joint of the Corsair HS80 and HS80 Max headsets. It provides essential mechanical support. The original part is prone to cracking, but this 3D-printable replacement is a reliable and easy-to-install alternative. While the headset is great, this part is poorly designed and breaks frequently. 

Features

• Fully compatible with the original Corsair part — you can reuse the original screws.
• Modified geometry optimized for 3D printing.
• Maintains nearly the same cross-section as the original injection-molded part, but with extra internal thickness for added strength.
• Designed to be durable yet printable using common consumer printers and materials.
• The geometry protrudes a bit over the curve of the part, this is unfortunately needed, to give it a nice surface finish  - this can be seen in the macro shots, but you won't notice it when wearing the headset :)

Printing Recommendations

• Material: PETG, ABS, or ASA (rigid but slightly flexible)
• Layer Height: 0.1 mm
• Nozzle Size: 0.4 mm
• Walls & Layers: 2 perimeter walls, 40 top/bottom layers (for a solid, strong part)
• Slicer Settings:
  • Disable “Detect narrow internal solid infill” for better strength
  • Set seam position to the back side
  • Set support direction to the back of the plate

Print Options

You have three choices:

1. Blank version (no side indicator)
2. Two-color print with left/right indicator — assign a different color to the “L” and “R” bodies

3. Single-color with indicator — delete the “L” / “R” bodies in your slicer before printing

    

   The included support structures in the .3mf files are essential for clean overhangs due to the part's thin geometry. For PLA or PETG, these supports are optional. For high-temperature filaments, they are recommended - they snap off easily after printing.

Assembly Instructions

1. Remove the damaged original part (don't damge the cable) and keep the screws.
2. Clean any remaining plastic from the headband slot.
3. Align the new part and press it in until it "clicks" into place.
4. Gently insert and tighten the original screws.