Summary

I lost one of the rubber fins for my JayBird BlueBuds (which are awesome!!) and they'd sometimes made my ear ache a little after many hours of use, from being a bit too stiff. So I decided to design my own replacement. You'll need a length of NinjaFlex to build these. The regular Replicator 2 extruder and build plate should work fine though.

Optimised heavily for 0.4mm extruder nozzles on FDM printers. Any MakerBot will work, or nearly any RepRap derived design. I've only tried slicing with MakerWare so your milage may vary with other slicers. I've included the MakerWare profile I used - it was tweaked a bit to make it print without any gaps.

Print Settings

Rafts:

No

Supports:

No

Resolution:

0.1mm

Infill:

n/a

Notes:

Here's the MakerWare profile I used for this, tweaked to print without any gaps with the normal spring loaded bearing pinch extruder on the Replicator 2:

{   "_bot" : "replicator2",   "_extruders" : [ 0 ],   "_materials" : [ "pla", "pla" ],   "adjacentFillLeakyConnections" : false,   "adjacentFillLeakyDistanceRatio" : 0,   "anchorExtrusionAmount" : 5.0,   "anchorExtrusionSpeed" : 2.0,   "anchorWidth" : 2.0,   "backlashEpsilon" : 0.050,   "backlashFeedback" : 0.90,   "backlashX" : 0.0,   "backlashY" : 0.090,   "bedZOffset" : 0.0,   "bridgeAnchorMinimumLength" : 0.80,   "bridgeAnchorWidth" : 0.80,   "bridgeMaximumLength" : 80.0,   "bridgeSpacingMultiplier" : 1.0,   "coarseness" : 9.999999747378752e-05,   "commentClose" : "",   "commentOpen" : ";",   "configPath" : "",   "defaultExtruder" : 0,   "defaultRaftMaterial" : 0,   "defaultSupportMaterial" : 0,   "description" : "Luna Horns ",   "doBacklashCompensation" : false,   "doBridging" : true,   "doDynamicSpeed" : false,   "doDynamicSpeedGradually" : true,   "doDynamicSpeedInteriorShells" : false,   "doDynamicSpeedOutermostShell" : true,   "doExponentialDeceleration" : false,   "doExternalSpurs" : true,   "doFanCommand" : false,   "doFanModulation" : true,   "doInternalSpurs" : false,   "doMixedRaft" : true,   "doMixedSupport" : true,   "doPrintProgress" : true,   "doPurgeWall" : false,   "doRaft" : false,   "doSplitLongMoves" : true,   "doSupport" : false,   "doSupportUnderBridges" : false,   "dynamicSpeedCurvatureThreshold" : 15,   "dynamicSpeedDetectionWindow" : 3.0,   "dynamicSpeedSlowdownRatio" : 0.30,   "dynamicSpeedTransitionShape" : 0.40,   "dynamicSpeedTransitionWindow" : 6.0,   "endGcode" : "",   "exponentialDecelerationMinSpeed" : 0.0,   "extruderProfiles" : [      {         "bridgesExtrusionProfile" : "bridges",         "feedDiameter" : 1.690000057220459,         "feedstockMultiplier" : 0.930,         "firstLayerExtrusionProfile" : "firstLayer",         "firstLayerRaftExtrusionProfile" : "firstLayerRaft",         "infillsExtrusionProfile" : "infill",         "insetsExtrusionProfile" : "insets",         "nozzleDiameter" : 0.40,         "outlinesExtrusionProfile" : "outlines",         "raftBaseExtrusionProfile" : "raftBase",         "raftExtrusionProfile" : "raft",         "restartExtraDistance" : 0.0,         "restartExtraDistance2" : 0,         "restartExtraRate" : 25.0,         "restartExtraRate2" : -1,         "restartRate" : 35.0,         "retractDistance" : 2.50,         "retractDistance2" : 0,         "retractRate" : 35.0,         "retractRate2" : 50,         "toolchangeRestartDistance" : 18.50,         "toolchangeRestartRate" : 6.0,         "toolchangeRetractDistance" : 19.0,         "toolchangeRetractRate" : 6.0      }   ],   "extruderTemp0" : 230,   "extrusionProfiles" : {      "bridges" : {         "feedrate" : 35.0,         "temperature_disabled" : 230.0      },      "firstLayer" : {         "feedrate" : 30.0,         "temperature_disabled" : 230.0      },      "firstLayerRaft" : {         "feedrate" : 35.0,         "temperature_disabled" : 230.0      },      "infill" : {         "feedrate" : 35.0,         "temperature_disabled" : 230.0      },      "insets" : {         "feedrate" : 35.0,         "temperature_disabled" : 230.0      },      "outlines" : {         "feedrate" : 35.0,         "temperature_disabled" : 230.0      },      "raft" : {         "feedrate" : 35.0,         "temperature_disabled" : 230.0      },      "raftBase" : {         "feedrate" : 10.0,         "temperature_disabled" : 230.0      }   },   "fanDefaultSpeed" : 0.50,   "fanLayer" : 1,   "fanModulationThreshold" : 0.50,   "fanModulationWindow" : 0.10,   "floorLayerCount_disabled" : 4,   "floorThickness" : 0.8000000119209290,   "gridSpacingMultiplier" : 0.990,   "infillDensity" : 0.250,   "infillOrientationInterval" : 90,   "infillOrientationOffset" : 0,   "infillOrientationRange" : 90,   "infillShellSpacingMultiplier" : 0.70,   "insetDistanceMultiplier" : 1.0,   "jsonToolpathOutput" : false,   "layerHeight" : 0.1000000014901161,   "layerHeightMaximum" : 0.270,   "layerHeightMinimum" : 0.120,   "maxSparseFillThickness" : 0.1000000014901161,   "maxSpurWidth" : 0.50,   "metadataOutput" : false,   "minLayerDuration" : 5.0,   "minRaftBaseGap" : 0,   "minSpeedMultiplier" : 0.30,   "minSpurLength" : 0.340,   "minSpurWidth" : 0.120,   "numberOfShells" : 2,   "purgeBucketSide" : 4.0,   "purgeWallBaseFilamentWidth" : 2.0,   "purgeWallBasePatternLength" : 10.0,   "purgeWallBasePatternWidth" : 8.0,   "purgeWallModelOffset" : 2.0,   "purgeWallPatternWidth" : 2.0,   "purgeWallSpacing" : 1.0,   "purgeWallWidth" : 0.50,   "purgeWallXLength" : 30.0,   "raftAligned" : true,   "raftBaseAngle" : 0.0,   "raftBaseDensity" : 0.6999999880790710,   "raftBaseLayers" : 1,   "raftBaseRunGapRatio" : 0.8000000119209290,   "raftBaseRunLength" : 15.0,   "raftBaseThickness" : 0.3000000119209290,   "raftBaseWidth" : 2.50,   "raftExtraOffset" : 0.0,   "raftInterfaceAngle" : 45.0,   "raftInterfaceDensity" : 0.3000000119209290,   "raftInterfaceLayers" : 1,   "raftInterfaceThickness" : 0.2700000107288361,   "raftInterfaceWidth" : 0.4000000059604645,   "raftModelSpacing" : 0.2300000041723251,   "raftOutset" : 4.0,   "raftSurfaceAngle" : 0.0,   "raftSurfaceLayers" : 2,   "raftSurfaceShellSpacingMultiplier" : 0.6999999880790710,   "raftSurfaceShells" : 2,   "raftSurfaceThickness" : 0.2700000107288361,   "roofAnchorMargin" : 0.40,   "roofLayerCount_disabled" : 4,   "roofThickness" : 0.8000000119209290,   "shellsLeakyConnections" : false,   "solidFillOrientationInterval" : 90,   "solidFillOrientationOffset" : -45,   "solidFillOrientationRange" : 90,   "sparseInfillPattern" : "hexagonal",   "splitMinimumDistance" : 0.40,   "spurOverlap" : 0.0010,   "startGcode" : "",   "startPosition" : {      "x" : -141,      "y" : -74,      "z" : 0   },   "supportAligned" : true,   "supportAngle" : 68.0,   "supportDensity" : 0.2000000029802322,   "supportExcessive" : false,   "supportExtraDistance" : 0.50,   "supportLeakyConnections" : true,   "supportModelSpacing" : 0.4000000059604645,   "travelSpeedXY" : 150.0,   "travelSpeedZ" : 23.0,   "version" : "3.7.0.148"}

JayBird Bluebud Ear Fin

JayBird Bluebud Ear Fin

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