Yeah, a closed design is going to be tough.  I have been mocking up some cups that level the band straps close to the face of the earcups to reduce pressure, and it seems to work.  Like you said, though, cumbersome.  IEMs are an obvious solution, anyone can use them already.  It would...

Maybe this should be in the BST area, but I figured that the people I want to talk to don't read much there. ;) I am looking for someone to help me out with making some custom headphones with a very specific twist: They need to be integrated with a ski goggle strap in some fashion.  Yes, I...