Varjo Aero - Sennheiser HD25 Adapter

This is a remix/mashup of several existing designs I found and modified to my needs. The clips fit on the Aero band nice and snug if you put them on where the band narrows just behind the tilt adjustment knobs and slide the clips back.

Updated 2/2/22

I updated the orginal parts that I had mashed together to better fit together and provide a more stable platform for the arms to rotate.

Note that this is designed with zero tolerance so depending on the accuracy of your 3d printer, you may need to clean up some of the holes in order to get a nice snug but not too tight fit.

I updated the orientation of the arms as it provides a more consistent profile for the ratcheting function of the headphones and also provides a much stronger print when being flexed.

The inner and outer knobs have built-in breakaway supports in the recessed holes facing the print bed.

Print with supports inside the keyholes of the arms and left/right clips in order to maintain the integrity of the shape which is needed to properly fit over the outer knob shaft.

I also included an arm with a 5 degree shallower angle which may help for anyone with a giant head (like me).

Requires 2-each of:

M3x20

M3 nylon lock nut

M3 washer

Printed in PLA

5 files plus a Prusa slicer 3MF project.

Print 2 each of the inner and outer knobs as well as the arms. 1 each of the left and right clips

I printed the arms as they are in the STL file with supports

Category: DIY