I must say I added cotton balls in the cups and they sound pretty good, and a rattle that I had in one cup is gone. I think that it was caused by the wire sitting on the driver and jumping when it was sitting on it. Check this site out (linked) they have a number of different tests for the...

I definitely agree here with using the ABS. The ABS tends to take more abuse than some of the other plastics and any UV exposure with the PLA can cause a definite brittleness that you would not expect otherwise. With the tolerance its going to be important for the surfaces so I would say that...

Use the crimp on a wire stripper if you have one.

Ok just semi-finished them. I still need to add some cotton it the cups to get the balance right between the 2 cups. They feel slightly bass heavy right now but I think that with some tuning I can get that down. I am getting a slight rattle in my right earcup and I thin that it is being caused...

Hey Guys,  Just giving an update to the project. The Cups came out perfect with a great resolution. I quickly removed the supports from the exterior with some wire snips and started to sand them with some 200 grit sand paper to start then followed with 400 up to 600. After I applied some...

Try and paint the part with some epoxy. It will help a bit with the crack formation.

Hey got to the local hardware store and get some JB Weld. Its an epoxy resin that happens to be just perfect for what happened to you. Just fill the hole up with JB weld and then just re-drill them out with a close size. Make sure that the size of the bit is a bit smaller than the post on the...

They were oriented in a specific way. The plates were oriented with the seal surface not touching the supports. Also the surface not being primarily in the XY plane will give better tolerance. For the cups I tried to keep supports on the outside and minimal on the inside. And for any inside I...

Here is an image of the build tray that is running currently. It is going to take 36 hours.   https://lh3.googleusercontent.com/-5nIwhhgjzHQ/WKdq-xzMTzI/AAAAAAABgcA/djM2l9cm0yARzEMJ7ktRWT6gxuZSG0WkACLcB/w327-h252-no/AlphaDogs.png   Anyone know how to be able to add photos here rather than...

With the flat parts you have to pay attention to the orientation. The printer has great accuracy in the x/y direction so as long as you angle the plates so they are not completely flat then you will get proper flatness. Other techniques can be making it so the last printed surface is the driver...

I am going to try and print these parts with the FormLabs SLA printer.  They have a new material called "Tough". Aside from being green it provides great dimensional accuracy +/- 10 micron in x/y and 25 micron in z. The finish as well is great leaving an almost polished surface. I attached a...