Well, I am not certain whether or not headphones are on the drawing board here. I am an apprentice to the master full range driver builder: Mr. Teramoto. Whatever he says goes... so it is 5 and 9 inch mind bending full rangers for home use.
I have been an avid headphone nut all along in this pursuit though.
Perhaps when I have my own skills up in 10-15 years (no joking...) I will try my hands at making perhaps washi paper headphone drivers or something funny like that. Just thinking out loud.
Plastic? Not a concern. It sounds like crap, even if used for the arch over the head...
I personally like some of the ATH offerings. Good for the money. comparing the w5000 to the r10, less speed, and a slightly smaller sound, but they were missing that high frequency resonance... and they were not as "annoyingly beautiful sounding." A little more like a good pair of speakers on your head.
There is SO much further that headphones could go. Trust me: it bothers me so much that people are missing "the boat" right now.
It is about marketing. Release a truely killer headphone within an existing product line (and market the hell out of it), and the lower end products sell better because people assume (correctly) that trickle down technology happens within the rest of the line, and then back up to the top.
It is like the racing program of any car manufacturer. Racing gives the production vehicles a little more "street cred" (Look at Subaru. Prime example.) Even if a little money is lost on the racing program, so what. It only seems to loose money when looked at all by itself around a grungey board room table with the man at the head of it wielding a mallet (or is that a hatchet) pointed at the poor sumguns that run the high end division.
Corporations are not always evil. Look at the grateful dead. It is just that all too often, the smell of money to the principal investors sitting on the board is stronger than a sense of duty to use one's resources to provide culture for society (and thereby make even more money, if done correctly).
I dunno. I would suggest that instead of seeing yourself as separate from the manufacturers, try to learn to make a headphone driver on your own or work within a company that is very good at it. Or just DIY it. That is what most manufacturers did initially.
You don't need an engineering degree to put a chisel in wood and then bend some clothes hangar pieces into a frame and glue some paper and a Neodynium magnet to it. better yet, a mini field coil. I think Ill call THAT the R11.
Hell. If anyone wants one, itll be 18000 bucks, pleeeaze.
-Clark