Summary

These expensive headphones reproduces very nice bass tones with very detailed highs. Unfortunately, earcup brackets are designed/produced with very bad plastic construction. My colleague's one was broken while he was listening to music. I decided to make him happy again by 3D printing a much robust construction.

Instructions

Reading STL files to Slicer:
- import Denon_AHD1100_headphones_earcup_fork_right.stl and place it on the bed as is. This will be right side earcup bracket.
- import the same file second time or copy the previous object, mirror on X-axis.
- import Denon_AHD1100_headphones_earcup_fork_lock.stl and place it 2 or more (spare) on the bed.
Support generation:
- Add support bars under two ends (4.5mm pins which would go into earcup sidewall holes) of each earcup bracket.
- Add support to the middle of the 4mm hole into which metal pin of head-rest would go in.
Slicer/Printer settings:
- 1.75mm PLA filament, black (fits better than gray/silver)
- 220C nozzle temperature
- 60C bed temperature
- 0.15mm 1st layer height
- 0.1 ~ 0.2 mm layer height (depending on the quality you desire)
- 0.8mm vertical shell (2 loops with 0.4mm nozzle diameter)
- 0.8mm horizontal shell (top/bottom, 8 loops @ 0.1mm layer height)
- 15~20% inner fill density
- 20mm/sec or less printing speed (perimeter, loops, everywhere)
Print
- 4m filament
- 4h printing time (with 0.1mm layer height)

Enjoy!

Denon AH-D1100 Headphones - Earcup brackets with screw-less locking mechanism