repaired audio plug on earbuds
A clumsy seat-mate on an airplane broke the audio plug on my earphones when he was trying to get out of his seat. I was able to remove the existing overmolded strain relief and resolder the connections, but I was left without a strain relief. I used some heat shrink tubing for a while, but was unsatisfied with the appearance.
Here's how I did it:
1) I used 3D CAD software to model up the strain relief geometry for the audio plug. 2) Using the original CAD as reference, I then created CAD for a 2-sided mold for the part. 3) I printed the mold parts out in a 3D printer (polyjet). 4) Needed some mold-release chemicals to allow the parts to come out of the mold, like greasing a cupcake tin. Didn't have any mold-release handy so I used olive oil. 5) Mold the Sugru around the bare audio plug by hand, while properly aligninge plug into the mold. 6) Close the mold with a C-Clamp and remove excess squeezed out of the mold. 7) 30hrs later, Done! Open the mold and enjoy the new overmolded strain relief I created!
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Wow Carson, this is amazing! You got an amazing hold of the shape when you demoulded - which of course is down to it curing before you demoulded - had you tried demoulding it while it was still uncured at all?
Jane.
Hi carsonlau, we have just blogged your gurus post, yay :)
Hi Jane: On my first trial, I did try and open the mold before 30 hrs and the part got deformed during the opening process. It really needs to cure 30hrs and then a few hrs more after removing from the mold. Without the mold release agent (olive oil in this case) the material will stick really well to the mold, especially since the mold has some texture from the 3D printer.
I considered spraying a coat of gloss paint into the mold to make the final part glossy as well, but was impatient and lazy.
Hi Carson, cool - just out of curiosity, how much did it cost you to 3d print that mold etc?
Unfortunately, it's much more expensive than buying a new pair of earphones. Depending on where you live, there might be a tech shop which offers access to machines like this for a membership fee.
I too would love a 3d printer but it just isn't happening for me anytime soon. Excellent fix and even though a tad more expensive, another item saved from landfill!
Epic!
I sure hope these were Bose or Bang & O.... Not some $10 Pair of Headphones!
Very Clever!
sugru
Very Impressive
cultureofone
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Very professional job. You make me wish I had a 3D printer!