Custom Bose 700 Headband

Resources

• Headband STL
• Swiveling Clip STL

Situation

The Bose 700 band feels great for the first half hour but quickly becomes uncomfortable after anything longer. I wanted a drop-in upgrade that would distribute the weight more evenly across my head without any permanent changes.

Task

Design a printable attachment that perfectly hugs the existing headband, roughly doubles the contact area, installs without tools or adhesives, and prints reliably.

Action

• 3D scanned the headset with an iPhone and Polycam
• Imported the scan and reference imagery into Blender
• Built a new model around the scan
• Applied a cloth simulation to flatten the curvature of the new headband, preserving the dimensions and allowing a flat print
• Ran through 3 prototypes:
  • 1. Headband only with no attachment mechanism to test for fit and comfort, held only by tape
  • 2. A keyhole swiveling clip design that would lock onto the existing band and hold the new larger band beneath
  • 3. Dialed in the final sizing, PLA thickness, and other tolerances

Result