Now for my design. My initial goal was to have the whole thing be 3D printable. And I was able to achieve that. The only room for improvement is to make the assembly better. As of now, there needs to be glue involved to keep certain pieces together.
For instance, as of now, these parts need to be glued together.

There will flanges to make sure they line up perfectly, but in the end it would be nice to have them clip together without glue.
All of the other parts though will assemble with out need of anything else.
Here are the sides of the headset and how they attach. There will be pins that attach the two pieces together. Much like the ones used in the hand to attach the fingers.

Here we see the part the goes over the top of your head and how it attaches to the headset. There is a dovetail joint the has a hard stop in the back to make sure it stays in place.

I am currently still working on the part that holds the phone and flips up. It will lock it in place and have openings to allow access to the headphone port.


I still need to finish the hinge and the way it will lock once flipped up.
If time allows I would like to make a part that then gets clipped to the part that hold the phone. It could be used to add a personal touch to each headset.
Once all assembled, this is what it will look like on a persons head.


The only thing that need to be added one assembled is the elastic band that goes around the back of the head. That get attached to the side pieces here:

I also need to model in a place for the headphone wires to put in. In the best case scenario, the wires would run through the model and the headphones would come out right by the ears on the side pieces.
The next step is to start printing the pieces that are fully modeled. The only problem is that my filament has not shipped yet. So I will need to use some from my work. I will want my final headset in the colors I chose, but printing in what i have at work will prove the parts can be printed in the first place. I also need to finish modeling a few parts and then print those. While my parts are being printed, I will use that time to do further research into the apps available and if there is anyone out there building apps for the same demographic I have in mind.

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