Bondic How-To - Fix Broken Headphones (Beats by Dre)

Bondic - Repairing Broken Beats by Dre Headphone Band

Dr. Dre took the world by storm with his headphone line. But what happens when you accidentally break them or any other headphones for that matter? Though this repair does require some more effort, you can use Bondic® to create a strong layer of plastic around the break, perfectly fixing and securing headphones back together. Just make sure you follow the steps correctly for the best results!

Suggested Tools:

Bondic
Dremel tool with an engraving cutting bit
Sand paper or nail file
Knife or sharp edged tool
Paint (to match color of headphones)

Never heard of Bondic? Click here for more information!

Bondic® is the World's First pocket 3D liquid plastic welder that allows you to fix, fill, mold, and even build almost anything. It will only solidify when you cure it with the included UV LED light, so you control the drying time. Once the UV light hits, it only takes 4 seconds to harden with no pressure needed and it will not stick to your skin. Keep in mind that Bondic® is NOT A GLUE and should not be used like one. It literally is a welding tool that uses a unique formula to build new plastic around two objects instead of “gluing” two flat surfaces together. Think of Bondic® closer to that of a 3D printer, creating new material where it has been lost. Additionally, for Bondic® to stick onto surfaces, it needs to be rough to allow the Bondic® fluid to seep into the pores of said objects and literally “grab” onto them when cured. We always like to think of Bondic as like gripping something with your hands. If you are trying to grab onto a smooth surface it will be really difficult to do so. But if the surface is rough, you can get a much better grip.

Drill Holes on Both Sides of the Band

Using your dremel tool, start by drilling small holes on both sides of the band a few centimeters (cm) away from the break (front & back).

These holes will act as "anchors" when you cure Bondic around it.

Roughen the Surface

Now, use a nail file and start roughening up both ends of the band around the holes you just drilled.

After that, take a knife and create vertical cut lines across the parts you just sanded. Try to sand/cut as much surface area as possible because Bondic needs a rough surface area to be able to "grab" onto things when it cures, so the rougher the surface, the stronger the hold!

Apply Bondic

Now that the surface area is nice and rough, you can begin applying Bondic.

Start off by filling up each hole you drilled with a small drop of Bondic (roughly 0.5mm) and curing it with the UV light. Continue filling up the holes layer by layer noting that Bondic will always cure to itself, the bond is so cohesive that every layer you make will fuse into one solid piece, just make sure you are not curing more than the recommended amount above at a time because the light will not be able to penetrate through.

Now that the holes are filled, continue adding additional layers of Bondic around the break, bonding the headphone band back together. Do not worry if you place Bondic in the wrong spot, the fluid will only harden if exposed to the UV light, so you have lots of time to get it right!

Once you have the fluid in the right spot, shine the UV light and watch it harden in seconds! Keep applying Bondic in small layers until you have surrounded the entire band. One trick to use to make sure it is fully cured is to simply tap the end of the light against the drop you are shining the light on, if the light does not stick then it is 100% hard plastic now.

Do not worry if you cured too big of a Bondic "blob" you can easily use a nail file and shave it down to the exact shape you want!

Sand Down Any Extra Material

Now that you have created a new layer of plastic around the broken band (which will resemble a coating of a piece of tape), you can use a nail file or sand paper to shave down any extra material you may have created to make the shape perfect.

Paint It!

This step is optional, but if you want to make your repair as seamless as possible, add a layer of paint.

In this particular case, I just used black nail polish. Feel free to use any paint you have on hand, even a marker will work.