{"id":8752,"date":"2026-10-07T09:32:55","date_gmt":"2026-10-07T09:32:55","guid":{"rendered":"https:\/\/dev95.site\/a-headset-fit-for-a-hackaday-writer\/"},"modified":"2026-10-07T09:32:55","modified_gmt":"2026-10-07T09:32:55","slug":"a-headset-fit-for-a-hackaday-writer","status":"publish","type":"post","link":"https:\/\/dev95.site\/ar\/a-headset-fit-for-a-hackaday-writer\/","title":{"rendered":"A Headset Fit For A Hackaday Writer"},"content":{"rendered":"<div id=\"dev95-984032157\" class=\"dev95-- dev95-entity-placement\"><script async=\"async\" data-cfasync=\"false\" src=\"https:\/\/pl27862732.profitableratecpmnetwork.com\/2ad7a50e0bbc23ac6801d7b77c501463\/invoke.js\"><\/script>\r\n<div id=\"container-2ad7a50e0bbc23ac6801d7b77c501463\"><\/div><\/div><div id=\"dev95-2312805566\" class=\"dev95-before-content dev95-entity-placement\"><p style=\"text-align: center;\"><strong>Stop wasting time on dead links! \ud83d\uded1 This smart platform automatically detects your device and country to give you the exact best offer instantly. Check it out now 100% free! \ud83d\udc47<\/strong><br data-sfc-root=\"ep\" data-sfc-pl=\"|||[]\" data-complete=\"true\" data-copy-service-computed-style=\"font-family: Arial, sans-serif, &quot;Noto Color Emoji&quot;; font-size: 16px; font-weight: 400; margin: 0px; text-decoration: none; border-bottom: 0px rgb(10, 10, 10);\" \/><a href=\"https:\/\/www.profitableratecpmnetwork.com\/pvhx5mbcc?key=ff7d362db3c20bc86fad685cc94f1fc4\">\ud83d\udd17 <strong class=\"rQesXe MPyX\" data-sfc-cp=\"\" data-sfc-root=\"ep\" data-complete=\"true\" aria-owns=\"action-menu-parent-container\" data-copy-service-computed-style=\"font-family: Arial, sans-serif, &quot;Noto Color Emoji&quot;; font-size: 16px; font-weight: 700; margin: 0px; text-decoration: none; border-bottom: 0px rgb(10, 10, 10);\">[Click here]<\/strong><\/a><\/p>\n<\/div><div>\n<div><img data-recalc-dims=\"1\" width=\"800\" height=\"450\" src=\"https:\/\/i0.wp.com\/hackaday.com\/wp-content\/uploads\/2026\/09\/jennys-headset-featured.jpg?resize=800%2C450&#038;ssl=1\" class=\"attachment-large size-large wp-post-image\" alt=\"\" style=\"margin: 0 auto; margin-bottom: 15px;\" decoding=\"async\" loading=\"lazy\" srcset=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/jennys-headset-featured.jpg 800w, https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/jennys-headset-featured.jpg?resize=250,141 250w, https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/jennys-headset-featured.jpg?resize=400,225 400w\" sizes=\"auto, (max-width: 800px) 100vw, 800px\" data-attachment-id=\"1166710\" data-permalink=\"https:\/\/hackaday.com\/2026\/10\/06\/a-headset-fit-for-a-hackaday-writer\/jennys-headset-featured\/\" data-orig-file=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/jennys-headset-featured.jpg\" data-orig-size=\"800,450\" data-comments-opened=\"1\" data-image-meta='{\"aperture\":\"0\",\"credit\":\"\",\"camera\":\"\",\"caption\":\"\",\"created_timestamp\":\"0\",\"copyright\":\"\",\"focal_length\":\"0\",\"iso\":\"0\",\"shutter_speed\":\"0\",\"title\":\"\",\"orientation\":\"0\",\"alt\":\"\"}' data-image-title=\"jennys-headset-featured\" data-image-description=\"\" data-image-caption=\"\" data-large-file=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/jennys-headset-featured.jpg?w=800\"><\/div>\n<p>I started writing this from a commuter train passing at speed through the outskirts of London, and my headset had just broken. The flexible joint that attaches one earpiece to the headband has snapped, leaving the earpiece dangling on its cable. This is annoying on its own, but what is annoying me enough to write about it is that this isn\u2019t the first time. This is only the latest in a succession of headsets I\u2019ve taken on the road with me has broken, not because of rough treatment, but simply due to flimsy or bad design. What on earth can I do about this?<\/p><div id=\"dev95-2215360945\" class=\"dev95- dev95-entity-placement\"><center>\r\n<script>\r\n  atOptions = {\r\n    'key' : '4ba6b6513c00e0ba76511f798ae56401',\r\n    'format' : 'iframe',\r\n    'height' : 50,\r\n    'width' : 320,\r\n    'params' : {}\r\n  };\r\n<\/script>\r\n<script src=\"https:\/\/www.highrevenueformat.com\/4ba6b6513c00e0ba76511f798ae56401\/invoke.js\"><\/script>\r\n\t<\/center><\/div>\n<h2>Failure Built-In<\/h2>\n<figure id=\"attachment_1166708\" aria-describedby=\"caption-attachment-1166708\" style=\"width: 400px\" class=\"wp-caption alignright\"><a href=\"https:\/\/i0.wp.com\/hackaday.com\/wp-content\/uploads\/2026\/09\/broken-EPOS.jpg?ssl=1\" target=\"_blank\"><img data-recalc-dims=\"1\" loading=\"lazy\" decoding=\"async\" data-attachment-id=\"1166708\" data-permalink=\"https:\/\/hackaday.com\/2026\/10\/06\/a-headset-fit-for-a-hackaday-writer\/broken-epos\/\" data-orig-file=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/broken-EPOS.jpg\" data-orig-size=\"1000,1000\" data-comments-opened=\"1\" data-image-meta='{\"aperture\":\"0\",\"credit\":\"\",\"camera\":\"\",\"caption\":\"\",\"created_timestamp\":\"0\",\"copyright\":\"\",\"focal_length\":\"0\",\"iso\":\"0\",\"shutter_speed\":\"0\",\"title\":\"\",\"orientation\":\"0\",\"alt\":\"\"}' data-image-title=\"broken-EPOS\" data-image-description=\"\" data-image-caption=\"\" data-large-file=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/broken-EPOS.jpg?w=625\" class=\"wp-image-1166708 size-medium\" src=\"https:\/\/i0.wp.com\/hackaday.com\/wp-content\/uploads\/2026\/09\/broken-EPOS.jpg?resize=400%2C400&#038;ssl=1\" alt=\"The earpiece of an EPOS headset, detached from its band.\" width=\"400\" height=\"400\" srcset=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/broken-EPOS.jpg 1000w, https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/broken-EPOS.jpg?resize=250,250 250w, https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/broken-EPOS.jpg?resize=400,400 400w, https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/broken-EPOS.jpg?resize=625,625 625w\" sizes=\"auto, (max-width: 400px) 100vw, 400px\"><\/a><figcaption id=\"caption-attachment-1166708\" class=\"wp-caption-text\">Failure inevitable: the whole headset relied on a tiny piece of plastic in the centre.<\/figcaption><\/figure>\n<p>The most recent three have been a JVC whose rotating joint allowing the earpiece to lie at a slight angle with my ear has failed, a quite expensive Logitech whose ear sponges failed closely followed by its USB cable, and now an EPOS whose ball joint has failed.<\/p>\n<p>I repaired the JVC and got a bit more life out of it and I\u2019ll have a go at repairing this EPOS, but that\u2019s hardly the point. I\u2019m paying not inconsequential money and I\u2019m getting good sound quality and electronics, but I\u2019m not getting anywhere near the mechanical quality I need. I could buy a set of tough DJ headphones such as the <a href=\"https:\/\/www.sennheiser.com\/en-gb\/\/catalog\/products\/headphones\/hd-25\/hd-25-506909\" target=\"_blank\">Sennheiser HD25<\/a>, but they don\u2019t come with a microphone, they\u2019re not a headset.<\/p>\n<p>So if I can\u2019t buy a decent headset without spending military grade money on one from an F16 fighter, what can I do to make my own? I\u2019m an <em>engineer<\/em>, damnit!<\/p>\n<p>At its most basic, a headset is a springy band that goes over the head, with an earpiece at its end. But a human head is not a cube with vertical parallel sides, it\u2019s a complex shape and every one is different. So those earpieces have to have some \u201cgive\u201d in them in order to fit comfortably against the ear. In the simplest case this is achieved by giving the earpiece a soft surround that moulds itself to the ear, but most headsets incorporate some articulation. The earpiece must rotate a little around a vertical line parallel with the ear, and also with a horizontal line at right angles to the axis of the ear. The EPOS managed both axes by means of a ball joint, while the JVC had a stirrup with pins to achieve the horizontal motion, and a circular joint \u2014 the part which broke \u2014 for the vertical. In both case the weak point was a thin part of the plastic moulding which broke, on the EPOS a short stalk for the ball in the ball joint, and in the JVC a similar stalk for the circular joint. Any design I come up with must avoid this type of weak point, and spread the load of an earpiece over considerably more material than my broken headset.<span id=\"more-1163896\"><\/span><\/p>\n<h2>So, How Do I Make This Thing?<\/h2>\n<figure id=\"attachment_1166707\" aria-describedby=\"caption-attachment-1166707\" style=\"width: 400px\" class=\"wp-caption alignleft\"><a href=\"https:\/\/i0.wp.com\/hackaday.com\/wp-content\/uploads\/2026\/09\/test-spring.jpg?ssl=1\" target=\"_blank\"><img data-recalc-dims=\"1\" loading=\"lazy\" decoding=\"async\" data-attachment-id=\"1166707\" data-permalink=\"https:\/\/hackaday.com\/2026\/10\/06\/a-headset-fit-for-a-hackaday-writer\/test-spring\/\" data-orig-file=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/test-spring.jpg\" data-orig-size=\"1000,1000\" data-comments-opened=\"1\" data-image-meta='{\"aperture\":\"0\",\"credit\":\"\",\"camera\":\"\",\"caption\":\"\",\"created_timestamp\":\"0\",\"copyright\":\"\",\"focal_length\":\"0\",\"iso\":\"0\",\"shutter_speed\":\"0\",\"title\":\"\",\"orientation\":\"0\",\"alt\":\"\"}' data-image-title=\"test-spring\" data-image-description=\"\" data-image-caption=\"\" data-large-file=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/test-spring.jpg?w=625\" class=\"wp-image-1166707 size-medium\" src=\"https:\/\/i0.wp.com\/hackaday.com\/wp-content\/uploads\/2026\/09\/test-spring.jpg?resize=400%2C400&#038;ssl=1\" alt=\"A 3d printed spring in white plastic\" width=\"400\" height=\"400\" srcset=\"https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/test-spring.jpg 1000w, https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/test-spring.jpg?resize=250,250 250w, https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/test-spring.jpg?resize=400,400 400w, https:\/\/hackaday.com\/wp-content\/uploads\/2026\/09\/test-spring.jpg?resize=625,625 625w\" sizes=\"auto, (max-width: 400px) 100vw, 400px\"><\/a><figcaption id=\"caption-attachment-1166707\" class=\"wp-caption-text\">This is my test spring print, and it\u2019s rather irresistible to play with.<\/figcaption><\/figure>\n<p>For the headband I could re-use the ones I have from my broken headsets, find one of the many 3D printable designs online, or the choice I took, design my own. And since I can re-use the drivers, microphone, and electronics, aside from designing a physical adaptor to take them, my problem becomes one of making a tough version of that articulated joint. And there my choice is to either replicate the ball or rotating joints of the originals but in a much tougher form, or to make a one piece design with elasticity and flexibility in the planes I need. It\u2019s time to break out OpenSCAD. I like things I can print in one go when it comes to builds like this one, as when it comes to assembly there is invariably a weak point where the different parts meet. So I\u2019m going for the latter choice, and making my earpiece mount on a spring rather than a two-piece joint. My spring is a simple zig-zag leaf spring, which is both robust, and has some movement in X and Y rotational axes, and Z displacement. It\u2019s an OpenSCAD library, and my little test print has all the compulsive manipulation of a fidget toy.<\/p>\n<p>So with a bit more OpenSCAD bashing I have a sliding print in place headband with my springs attached. You can take a look at it <a href=\"https:\/\/github.com\/JennyList\/jennys-headset\" target=\"_blank\">in this GitHub repository<\/a>, and even modify it for a broken donor headset of your own if you want.As I write this it\u2019s not yet printed, the 3D printer gods have not smiled upon me with extra speed. Will my crafty print in place springs solve the problem? At least if they break I have only myself to blame.<\/p>\n<\/div>\n<div class=\"pvc_clear\"><\/div>\n<p id=\"pvc_stats_8752\" class=\"pvc_stats total_only  \" data-element-id=\"8752\" style=\"\"><i class=\"pvc-stats-icon large\" aria-hidden=\"true\"><svg aria-hidden=\"true\" focusable=\"false\" data-prefix=\"far\" data-icon=\"chart-bar\" role=\"img\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" viewBox=\"0 0 512 512\" class=\"svg-inline--fa fa-chart-bar fa-w-16 fa-2x\"><path fill=\"currentColor\" d=\"M396.8 352h22.4c6.4 0 12.8-6.4 12.8-12.8V108.8c0-6.4-6.4-12.8-12.8-12.8h-22.4c-6.4 0-12.8 6.4-12.8 12.8v230.4c0 6.4 6.4 12.8 12.8 12.8zm-192 0h22.4c6.4 0 12.8-6.4 12.8-12.8V140.8c0-6.4-6.4-12.8-12.8-12.8h-22.4c-6.4 0-12.8 6.4-12.8 12.8v198.4c0 6.4 6.4 12.8 12.8 12.8zm96 0h22.4c6.4 0 12.8-6.4 12.8-12.8V204.8c0-6.4-6.4-12.8-12.8-12.8h-22.4c-6.4 0-12.8 6.4-12.8 12.8v134.4c0 6.4 6.4 12.8 12.8 12.8zM496 400H48V80c0-8.84-7.16-16-16-16H16C7.16 64 0 71.16 0 80v336c0 17.67 14.33 32 32 32h464c8.84 0 16-7.16 16-16v-16c0-8.84-7.16-16-16-16zm-387.2-48h22.4c6.4 0 12.8-6.4 12.8-12.8v-70.4c0-6.4-6.4-12.8-12.8-12.8h-22.4c-6.4 0-12.8 6.4-12.8 12.8v70.4c0 6.4 6.4 12.8 12.8 12.8z\" class=\"\"><\/path><\/svg><\/i> <img data-recalc-dims=\"1\" loading=\"lazy\" decoding=\"async\" width=\"16\" height=\"16\" alt=\"Loading\" src=\"https:\/\/i0.wp.com\/dev95.site\/wp-content\/plugins\/page-views-count\/ajax-loader-2x.gif?resize=16%2C16&#038;ssl=1\" border=0 \/><\/p>\n<div class=\"pvc_clear\"><\/div>\n<div id=\"dev95-2770886465\" class=\"dev95-after-content dev95-entity-placement\"><p style=\"text-align: center;\"><strong>Finally, a link that actually works for your region and device! \ud83c\udf0d Get instant access to the top exclusive offers tailored just for you right now. Don&#8217;t miss out, click here! \ud83d\udc47<\/strong><br data-sfc-root=\"ep\" data-sfc-pl=\"|||[]\" data-complete=\"true\" data-copy-service-computed-style=\"font-family: Arial, sans-serif, &quot;Noto Color Emoji&quot;; font-size: 16px; font-weight: 400; margin: 0px; text-decoration: none; border-bottom: 0px rgb(10, 10, 10);\" \/><a href=\"https:\/\/www.profitableratecpmnetwork.com\/uzeja8ahze?key=bc876be53d6ad0ff6370ab8ea030e479\"><strong>\ud83d\udd17 [Click here]<\/strong><\/a><\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>I started writing this from a commuter train passing at speed through the outskirts of London, and my headset had just broken. The flexible joint that attaches one earpiece to the headband has snapped, leaving the earpiece dangling on its<\/p>\n<div class=\"hosteria-entry-more\"><a href=\"https:\/\/dev95.site\/ar\/a-headset-fit-for-a-hackaday-writer\/\" class=\"no-underline font-light  group-hover:text-primary-800 dark:group-hover:text-primary-300 py-1\">Read more &gt;&gt;&gt;<\/a><\/div>\n<div class=\"pvc_clear\"><\/div>\n<p id=\"pvc_stats_8752\" class=\"pvc_stats total_only\" data-element-id=\"8752\" style=\"\"><i class=\"pvc-stats-icon large\" aria-hidden=\"true\"><svg aria-hidden=\"true\" focusable=\"false\" data-prefix=\"far\" data-icon=\"chart-bar\" role=\"img\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" viewbox=\"0 0 512 512\" class=\"svg-inline--fa fa-chart-bar fa-w-16 fa-2x\"><path fill=\"currentColor\" d=\"M396.8 352h22.4c6.4 0 12.8-6.4 12.8-12.8V108.8c0-6.4-6.4-12.8-12.8-12.8h-22.4c-6.4 0-12.8 6.4-12.8 12.8v230.4c0 6.4 6.4 12.8 12.8 12.8zm-192 0h22.4c6.4 0 12.8-6.4 12.8-12.8V140.8c0-6.4-6.4-12.8-12.8-12.8h-22.4c-6.4 0-12.8 6.4-12.8 12.8v198.4c0 6.4 6.4 12.8 12.8 12.8zm96 0h22.4c6.4 0 12.8-6.4 12.8-12.8V204.8c0-6.4-6.4-12.8-12.8-12.8h-22.4c-6.4 0-12.8 6.4-12.8 12.8v134.4c0 6.4 6.4 12.8 12.8 12.8zM496 400H48V80c0-8.84-7.16-16-16-16H16C7.16 64 0 71.16 0 80v336c0 17.67 14.33 32 32 32h464c8.84 0 16-7.16 16-16v-16c0-8.84-7.16-16-16-16zm-387.2-48h22.4c6.4 0 12.8-6.4 12.8-12.8v-70.4c0-6.4-6.4-12.8-12.8-12.8h-22.4c-6.4 0-12.8 6.4-12.8 12.8v70.4c0 6.4 6.4 12.8 12.8 12.8z\" class=\"\"><\/path><\/svg><\/i> <img loading=\"lazy\" decoding=\"async\" width=\"16\" height=\"16\" alt=\"Loading\" src=\"https:\/\/dev95.site\/wp-content\/plugins\/page-views-count\/ajax-loader-2x.gif\" border=\"0\" \/><\/p>\n<div class=\"pvc_clear\"><\/div>","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"fp_fajr_begins":"","fp_fajr_iqamah":"","fp_dhuhr_begins":"","fp_dhuhr_iqamah":"","fp_asr_begins":"","fp_asr_iqamah":"","fp_maghrib_begins":"","fp_maghrib_iqamah":"","fp_isha_begins":"","fp_isha_iqamah":"","fp_midnight":"","fp_midnight_name":"","fp_sunrise":"","fp_single_prayer_begins_title":"","fp_single_prayer_iqamah_title":"","fp_prayer_times_for_today":"","fp_hijra_date":"","fp_fajr_name":"","fp_dhuhr_name":"","fp_asr_name":"","fp_maghrib_name":"","fp_isha_name":"","fp_sunrise_name":"","fp_currentDate":"","fp_current_time":"","fp_current_title":"","fp_current_location":"","fp_masjid_name":"","fp_prayer_title":"","fp_next_prayer_iqamah_time":"","fp_next_prayer_iqamah_title":"","fp_next_prayer_begins_time":"","fp_next_prayer_begins_title":"","fp_next_prayer_title":"","_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_feature_clip_id":0,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_post_was_ever_published":false},"categories":[37],"tags":[],"class_list":["post-8752","post","type-post","status-publish","format-standard","hentry","category-posts"],"a3_pvc":{"activated":true,"total_views":0,"today_views":0},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.6 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>A Headset Fit For A Hackaday Writer - Dev95<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/dev95.site\/ar\/a-headset-fit-for-a-hackaday-writer\/\" \/>\n<meta property=\"og:locale\" content=\"ar_AR\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"A Headset Fit For A Hackaday Writer - Dev95\" \/>\n<meta property=\"og:description\" content=\"I started writing this from a commuter train passing at speed through the outskirts of London, and my headset had just broken. 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