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With summer around the corner – it can only mean one thing! Holiday! Check out our maker project of the week – a fold-able 3D printed headset for all you jet-setters keen on compact travel-light products.

Most “affordable” headsets (the ones you pack for the plane or train) are always bulky and sometimes awkward to travel with – so BCA decided to modify one, led by  Chief Creative Officer, Mitesh Patel.

We began with something similar to below that we picked up for less than £3.




The middle section was then replaced with a 3D printed triple hinge design. Check it out.




This entire 3D printed headset has been printed as one piece with hinges at the centre and sides. Snap fittings were also used to make it easy to assemble and dissemble when traveling.








Even as “experts” we we didn’t get this right first time. Here are all our development models where we tested different types of 3D printed hinges, snap fittings and orientation.




If you would like to learn more about this project, 3D printing education or how to create 3D printed hinges  (part of our Additive Manufacturing Design and Manufacture course) then please contact us on [email protected] – don’t forget to follow us on Twitter and LinkedIn.