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After a year of so of reiterating (38 reiterations, including 5 major ground-up revisions), I've finally made a model that I'm proud to share.
Same premise as before: Holds a Knowles TWFK/SWFK and a 9-10mm dynamic driver. It'll also hold smaller BAs with a dab of glue/blutak to prevent it from rattling around (the BA chamber is designed so that it won't fall through).
*note: These versions come with "pre-drilled" holes for cables, you might need to expand the hole if you're using thicker cables. Please see here for no-holes for other DIY ideas.
No more cavities
The case is SOLID except driver chambers and sound bores. No more leaks and echoes.
Integrated Knowles damper slots
separately for the BA and dynamic units. Use a smidge of glue to secure them. Which leads us to...
Sound bores are fully integrated into the shell, no more fiddling around with silicone tubes.
Horn-bore chamber for the BA
Similar principles as CA's TAEC. This helps emphasize the highs for some sweet extension.
Fillet-ed to hell and back
Smooth as a baby's bottom. No angular corners to irritate your ears.
Refined 3D design process
This is really more of a boon for Shapeways - printability is like 9001x more consistent, and the STL files are tiny now, I can fit both models into one upload easily. Helps save some 'processing' costs.
+ some sweet internal wiring channels
Please note before ordering:
It is super highly recommended that you 'finish' the outside of the model with a layer or 2 of hard UV-resistant varnish/lacquer. It really solidifies the structure, stops further 'curing' (which makes things brittle after a few months), and plugs up pores. Some workarounds to flaws of 3D printing.
These models have a dynamic driver side height restriction of ~3.54mm (see photo). My faceplates add another 0.5mm z-height, so that gets you ~4.2mm clearance.I will make a taller version it if there's demand.
Have a small filer ready (jewelry polishing kits can be gotten for ~$2 on certain sites). Sometimes the print will be a little thicker than usual, making the fit a little too snug. It should not happen since I have added like 0.3mm buffer to this model, but sometimes shit happens.
Large cutouts for 2-pin/mmcx sockets have been abandoned for non-removable wiring. These models are crazy space efficient, mmcx and 2-pin female assemblies take way too much space. + it adds some annoying issues for you, the builder. These are designed for cables where you pass it through a hole and knot it, as with 99% of oem designs. If you really need to add removable cable sockets, have to go at it with a tiny dremel/drill.
Buy with faceplates (separately), or DIY with wood/carbonfiber/cork/anything!
Fits 3.5-4.2mm diameter wax guards optional but recommended.(PM me if you need URLs)
Insertion "tube" OD is 4.95mm Choose eartips accordingly. Most non-Shure/Etymotic ones fit.
Insert and secure dampers before installing drivers. Choose your dampers first, they are not easily changed! (generally I recommend brown for the BAs and brown/yellow/red for the dynamics).
Be very careful with installation if you order steel/other metal materials. They might short out.
I would love to hear your feedback! If anything pleases or displeases you, or have requests such as other Shapeways materials, please let me know! I wish to improve and create better products for the community :)
*minor update 23/10: improved nozzle area to community feedback; now has improved tips compatibility, comfort and strength (no breakages before, either, just did it while I was in there editing anyway).