Resono DIY Headphones
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| print+ |
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| homebrew headphones |
There are few DIY designs of headphones on the web. So, I decided to build my own.
My criteria were to build portable, light, 3D-printable, Bluetooth Headphones.
The Resonos are born
First of
all I searched on the Internet for DIY Headphones and I found this interesting piece:
https://www.print.plus/ I like the
headband but didn’t like the special drivers that u need to buy from them. So,
I thought to maybe use the headband and build some custom cups.
I found
some old parts that I could use at home. I had a couple of old headphones which I could reuse. By searching the web, I found the Qualcomm CSR8645
Bluetooth receiver. And I took the Battery of an old phone.
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| csr8645 (with amp) |
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| battery |
My first
attempt to build a pair of in Ear Bluetooth Headphones failed because the
components are too big to fit them in a nice package. So, my second idea was to
build on Ear Headphones. In my opinion this is the best compromise between size
and portability.
I found the
print+ headphone project, which really appealed to me. But the problem is that
they use some proprietary driver size and have no BT. So, I moded their design
and came up with this:
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| model |
It’s
basically the same print+ headband and the back of the ear parts with more
space for battery and BT receiver. In the
right ear part, there is the csr8645, the headphone amp (more on that later)
and a switch. In the left ear part, there is the old phone battery and a micro
usb charging port. I printed this with a Prusia i3 with 30% infill. The headband was also printed with 30% infill. But it was pretty stiff, so i put it into the oven on 100°C for 1:30 min and bend it outwards a little bit. Very hacky, but it works ^^
I scavenged
an old pair of Creative headphones and disassembled them. And then I modelled a
pair of outer shells that would fit the drivers.
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| assembled headphones |
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| headphone cups |
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| old Creative drivers |
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| ear pad mount |
I will
attach the files, but I don’t know how useful they will be without the exact headphones.
I even don’t know the model of the Creative Headphones. But actually most headphones have a 70mm diameter so you could be lucky and find some parts that fit. Also on Amazon there are a ton of ear pads that have 70mm diameter so you can get these there. For the headband just head over to https://www.print.plus/download and download any of the package there. All packages contain the same headband they only differ in the cups. Oh, and I forgot to
model the wholes for the screws, so I drilled them ^^
Electronics
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| inside the Resono |
The next thing I did was to buy a Bluetooth receiver. I bought a csr8645 by Qualcom. It has Bluetooth 4.0 and AptX support, which gives you pretty good audio quality over Bluetooth.
There are
many versions of this bord on eBay. They cost around 10€ if you order from China.
I used one which had no headphone amp, but there are also versions with an amp.
There are versions with no amp, headphone amp or 5W stereo amps for little
boomboxes. Pay attention to get one with a HEADPHONE amp. Headphones require
around 150mW power so a 5W stereo amp will blow your ears. Trust me I learned
this the hard way. Here is a little guide:
It is really hard to distinguish them. You have to read the description carefully. Many resellers sadly don't even know what they sell. This is very annoying.
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| no amp |
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| 5W amp |
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| headphone amp |
If you get
a csr8645 without a headphone amp, as I did, you will need a dedicated amp. I
took the TPA6132 for around 5€.
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| TPA6132 |
Connect the TPA6132 to the outputs of the
csr8645.
For power I
am using an old 3,7V mobile battery with 600mAh. It lasts for about 1 week of
music listening which is pretty good in my opinion.
Connect the
battery – and + to the csr8645 and the TPA6132 GND and VIN.
Next up the
micro usb charging port.
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| usb charger board |
There a plenty of these on eBay. Just get a charger
for 1 cell with micro usb input. Anyone will do.
Now connect
the GND and BAT output of the charger to the battery – and +.
Here is a scheme
for all the wiring:
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| scheme |
Links
CSR: https://eckstein-shop.de/CSR8645-Bluetooth-Stereo-Audio-module-Adapter-Board-with-IO-customTPA: https://eckstein-shop.de/TPA6132-Differenz-Balanced-Verstaerker-Board-Einzelhafen-HIFI-23V-55V
print+: https://www.print.plus/
Homebrew Headphones: https://homebrewheadphones.com/
Resono STLs: https://1drv.ms/u/s!AoWHXfp9cYCynONQmvrVN3FOiotORg?e=dlYhhe
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