Improved 5 Magnet Disney Ears Headband

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An improved version of the 5 magnet headband for disney ears. 

These solve 2 major problems my kids had with the originals, and one that I had:

1. Pressure points on the originals would irritate the skull during extended wear
2. Quick forward or backward head movements would send the ears flying because the magnets were not strong enough to withstand the torque in the front/back direction.
3. Installing the magnets is difficult and installing them the wrong way around by mistake makes the print scrap because getting them back out is impossible.

To solve the pressure point issue, I inverted the curvature at the bottom of the band, and made the band slightly thicker. This gives a larger more gradual contact point with the head, which should decrease the pressure the headband puts on the head. The kids and I have worn these for extended periods and even forgot they were on.

Making the band slightly thicker also allowed for increased stability of the ears. The thicker band has room to put walls around the base of the ears, which keep the ears from twisting at the magnets directly. This makes them massively more stable. You can shake the headband pretty violently in your hand and the ears stay on. 

The magnet holes are properly sized for a light press install with a slight lead-in to get them started without them going sideways. The magnet holes also have a smaller hole going all the way through, so if you repeatedly install them backwards like me, you can push them back out from the backside with a small screwdriver.

Ten 6x3mm magnets are required per headband. You might be able to get away with only using 3 (one in the center and one on each end) but I have been testing with 5 and the ears are very stable with 5. I would recommend printing a magnet insertion tool if you plan on making many of these, especially if you plan on making many ears as well. 

Like all of the printed ears we have tried, we had to add these rubber headband grips due to the weight of the ears. I am working on integrating a similar feature, but the slick nature of the 3D printed plastic may just make it impossible. I will update the model if I find an integrated solution for additional grip.

Update: I have added a print profile for a headband with magnets in the center, which will attach to a bow. The bow is attached with 2 6x3mm magnets, located 14mm apart (center to center). I have included 2 bow examples in another print profile. Both are multicolor prints but either can be printed solid without issue. The “Original Bow” profile has the same geometry as the “Original” file, which features flared ends and is more suitable to larger heads. The “Headband Only” version matches the Added Grip geometry, which a slightly tighter on the head.

Modular 5 Magnet Ears with Customizable Inserts - Free 3D Print Model - MakerWorld   I have also designed a new set of modular ear frames. These frames utilize interchangeable thin inserts that print quickly. The design avoids printing many frames with many magnets, and instead relies on a much more compact friction fit insert, to reduce the amount of stuff to carry when at the park. It also provides the ability to have centrally mounted, double sided designs without the need for support material.