I'm a product design student considering doing a custom-fit headphone project. You can get IEMs custom fit to your ears, but as far as I'm aware there's nothing comparable for on-ear (or over-ear) headphones. With 3d printing being especially suited to personalised and user-fit products, and since flexible materials can now be 3d printed as well, I believe both ear-pads and cans could be 'tailored' to the customer.
I would like to hear your thoughts on this, since I'm far from an expert on headphones. Is this something you would find interesting? Would ear-pads shaped to your ears be better than normal flat pads?
[Edit: I've realized I might have put this in the wrong forum - if a mod thinks this thread fits better in the DIY section, then please feel free to move it.]
Edited by nikparo - 2/11/14 at 1:22pm