3d Printed Headphone Case

Due to the small footprint and odd Form Factor of the Koss Porta Pro Headphones, it is particularly hard to find reliable and high quality means of storage at a reasonable price.

The Workflow for most 3D printing projects occurs as follows.

Firstly the model is designed within a Computer-Aided Design (CAD) software, for me, Autodesk Fusion 360, and is exported as an STL file.

Next. the STL is imported and set up in a Slicing software of which utilizes a model file and generates a series of steps of which the 3D printer must execute in order to produce our model, based on our desired settings. Such is transferred to the printer via a file format known as G-code, which is a series of universal commands that are read and understood by our 3D printer and is standard on most Computer-Aided Manufacturing (CAM) Machines.

Next, all commands and G-code are transferred wirelessly to the Printer via a dedicated 3D printing web server operated within a Raspberry pi 3 Embedded Computer, which is connected to the serial input of the 3D Printer.

The 3d model is then printed and then "Finished", or processed via removal of unwanted stringing and artefacts. The model can then be assembled.

The Design Process and application of this Workflow can be seen below.

At this step, it was decided the case will take the form of two halves of which will enclose the headphones and clasp into place, and will be printed in multiple parts

Via the use of a digital Vernier Caliper, pertinent dimensions of the Headphone case were recorded and tolerances for the design were recorded.

These general dimensions were used to generate a rough outline of the Headphone case, containing the required dimensions.

A mock-up model was then Printed to ensure the feasibility of design and model revisions were made.

At this step, there are 2 main mechanisms of which are to be integrated into the model.

Firstly, a Magnetic Clasp Mechanism was chosen to close the case, similar to that used in the Project Robotic Pen. Holes and groves for these magnets were to be added to the model.

Secondly, a guidepost system was chosen to ensure both halves of the case, to prevent lateral displacement of the case halves whilst transporting the case, releasing the Magnetic Clasp Mechanism.

After which the model was split into multiple sections for fast and cost-effective 3D Printing. The major flat circular surfaces of each shell were isolated to be printed separately from the bulk model for best printing.

The model was then converted and saved as an STL file.

Such file was then imported into a Slicing Software, which utilizes a model file and generates a series of steps of which the 3D printer must execute in order to produce our model, based on our desired settings. Such is transferred to the printer via a file format known as G-code, which is a series of universal commands that are read and understood by our 3D printer and is standard on most Computer-Aided Manufacturing (CAM) Machines.

More about this Processing Segment of the Workflow can be found in the 3D Model Processing Workflow page

The parts can now be printed via the 3D Printer.

The parts are then cleaned after printing and the Skin Layers glued to the main model via ALL-PLAST Plastic solvent Glue. The neodymium magnets are then secured into their spaces and a patterned fabric sheet is adhered to the back of the multi-coloured faceplate to protect the headphones during travel.

The Faceplate and Main Housing were then adhered to using ALL-PLAST Plastic solvent Glue.

Via an execution of my typical design process, a custom 3D Printed Headphone case for the Koss Porta Pro Headphones, which is magnetically clasped, high quality and cost -ficient and protects the pair of headphones reliably during transport.