Ugliest headset repair ever.

[Pommie]

A couple of days ago my headset snapped. I tried using tape to fix it, no good. I eventually printed a 3D splint for it and filled splint with hot melt glue and stuck it on. Result,

Very ugly but it worked.
I used openSCAD to design it which I recommend if your into 3D printing.
Here's the code.

$fn=200;
id=180;     //average diameter of the headphone ring
w=23;       //width of the headphone band
th=9;       //thickness of the headphone band
t=5;        //thickness of the wall
l=40;       //length of the part

translate([0,id/2,l/2])
rotate([0,90,0])
difference(){
    cylinder(r=id/2+th/2+t,h=w+2*t,center=true);
    cylinder(r=id/2-th/2-t,h=w+2*t+2,center=true);
    translate([0,0,t/2+0.1])
    difference(){
      cylinder(r=id/2+th/2,h=w+t,center=true);
      cylinder(r=id/2-th/2,h=w+2+t,center=true);
    }
    translate([id/2+l/2,0,0])
    cube([id,id+20,2*w],center=true);
    translate([-id/2-l/2,0,0])
    cube([id,id+20,2*w],center=true);
    translate([0,50,0])
    cube([id,id,2*w],center=true);
}

And the object,

I doubt this will come in useful for anyone but might encourage people to have a look at openSCAD.

Mike.

 

[unclejed613]

black filament would have been a better choice...

 

[Pommie]

black filament would have been a better choice...

I was aiming for ugliest.

Mike.

 

[Malinga the professor]

It's cool.
For me I always make some wholes; two in each side and then connect them using sewing thread in a crossing way.
After that I apply some super glue and black tape on top it looks nice