Headphone Repair

I recently got new headphones (JBL Quantum 200s)which I very much enjoy except for their incredibly weak frame. The first time they broke was when my brother sat on them which I simply super glued them together and taped them up, this joint worked surprisingly well because the second time they broke it was just above the previously broken part. No big deal right? I just got the glue which held nicely until my brother decided to use my headphones and mysteriously they broke again which made them unusable once more. It was then when I decided to make a replacement for the part to not only restore the headphones but to make the part stronger.

If you are 3d printing a replacement part for the quantum lineup from JBL all you will need is a

• 3d printer + 3d printer fillament
• screwdriver
• 2x m3 screws + 2x m3 nuts
• a guitar pick (optional)

I recommend printing the part at 4 perimeters with 90 percent infill at.1 mm height.

the step and STL files are below

to begin disassembling your headphones, I recommend using a guitar pick to pry open the gap between the foam part of the headphones and the shell until you can get a finger under and pry the foam pad off the shell by disengaging the clips. once you do this you will see 4 screws that will need to be unscrewed and saved for reassembly.

once you take the speaker off the shell you will be able to pull apart the swivel part that is being replaced, notice the notches that are holding the part in place because you might need to bend the 3d printed part if it does not line up perfectly with the notches. once you do this you might need to break the part from the upper headpiece since it is press-fitted, mine was already broken so I did not have to do this step.

once removing the old part you can bend the new 3d printed part to snap in place in the shell, notice the wire path the wire has to go through to not be damaged. after this line up the top-notch with the part that attaches to the headpiece and screws it in, once you do this make sure that you place the wire in the wire path so it is not damaged and screw the speaker and snap-in back in the foam piece.

in summary, after using the headphones for 2 weeks I did not notice any wear in the part I think it will hold up but only time will tell.

I am very happy I did not have to buy a new pair of headphones and recommend that instead of throwing away broken appliances, try and see if you can fix them.