Armadillo Headphones Assembly

Printing the Parts

The following parts need to be printed before the assembly can begin. The suggested infill levels are based on PLA. If you are using a stronger material such as ABS, it possible to use less infill.

Part Qty. Recommended Infill
Headband 1 75%
Plug 2 30%
Locker Left 1 30%
Locker Right 1 30%
Adjuster 2 50%
Rotator 2 80%
Grill 2 30%
Cup 2 85%

Print Orientation

Each part has been designed with a specific print orientation in mind. This is in order to maximise strength and keep the need for supports at a bare minimum. See the images below for the suggested print orientation (blue surface against the print-bed).


Only a trivial amount of support material is required to print the Armadillo Headphones. The two parts that require supports when printing are the Cups and the Adjusters. See images below for suggested support placement.

Ear Cup Supports
Adjuster Supports


The headphones can be assembled without using any screws in about 10 minutes.

Step 1- Prepare the Headband

The first step is to prepare the headband. As it comes of the print bed it is possible that the links are stuck together due to minor imprecisions when printing. To solve this simply break each joint free by pressing against a flat surface as shown in the picture below.
3D printed headband

If you feel that you are applying a lot of force and the joint is still stuck together, try using a knife in the crack between the links to loosen the joint.

Step 2- Prepare the Cable

Take the audio cable and make a knot about 2cm from the each end. This knot will assure that the cables are not detached from the drivers when the cable is pulled with force.
Knot on cable

Step 3- Solder the Cable to the Drivers

Heat up your soldering iron an prepare to attach the cable to the 40mm audio drivers. Each cable-end will have two separate wires sticking out already. Solder each of these to the driver’s poles.
40mm audio drivers backside
The drivers will sound nicely whichever way you attach the cable to the poles. However it is a good practice to attach with the same polarity on both drivers as it will improve the synchronisation of audio between left and right channel.

Step 4- Insert the Drivers

Put the drivers into the ear cups and press them firmly into place. Make sure that the knots of the cable ends are on the inner perimeter of respective ear cup. This is so that no force is absorbed by the soldering points when the cable is pulled.

Be careful to never touch the membrane as that could damage the drivers.

(Optional) Step 5- Create seal using hot glue

In some cases hermetically sealing the driver has shown to improve sound quality. If you test the drivers and feel they lack clarity, this will help.

Simply apply a precise line of hot glue along the perimeter of the driver. Be careful not to get glue on the membrane as that could destroy the drivers. Also avoid getting glue on the threads as that makes it difficult to attach the padding later.

Note that you should not glue the the cable hole as the air still needs some hole to move through.

Step 6- Attach the Earpads

Pull the earpadding around the Grill part. Next take each a Cup with the driver in it, and screw the Grill together with the earpadding into the Cup. At the end the fabric of the padding should be squeezed between the Cup and Grill in such a way that it cannot be easily pulled off.
Assembling the Ear Cups
If you are having problems screwing the Grill into the Cup, try screwing the pieces back and forth without the padding attached. This will smooth out any minor imperfections in the threads, making the assembly easier.

Step 7- Attach the Adjusters

Attach the Adjusters to each ear cup as shown in the image. The Plug piece should fit tightly into the hole of the Adjuster so that it will not slide out during use.
3D printed adjusters

Step 8- Attach the Rotators

To attach the Rotators to the Headband, insert them at a 90 degree angle as shown in the picture. If you are having trouble doing this please make sure that you have rotated them in the right direction as they will only go in one way.
Attaching cups to 3D printed headband

Once the Rotators are attached, rotate them 90 degrees again to lock them to the headband.

Step 9- Attach the Earcups

Attach both earcup assemblies by inserting the Adjusters into the Rotators. If you feel a lot of resistance when doing this, clean the edges of the adjusters using a knife or sandpaper so that there is no residual material left.
Attachment of 3D printed Headband

Step 10- Lock the Assembly

Before you lock the assembly you need to identify which is the left and right channel in your setup. You can do this by connecting the headphones to a device that is only playing on a single channel. If you are using iOS you can achieve this by going into the “Accessibility Settings”.
iPhone Channel Control

Once you have identified which driver is left/right, attach the correctly labeled Locker piece to respective Adjuster.
3D printed headphones snap fit assembly

And you are done! It is now impossible to disassemble the headphones without first forcefully removing the Locker pieces.

3D printed headphones unfolded

If you have any feedback on the design we would love to know! Please your suggestions to and we will incorporate them in the next update.