Bone Conductor Headphone Case

This is a 3D Printed Protective Carrying Case for traveling with NANK Bone Conductor Headphones. This was designed for the "NANK Runner Diver2" model, but may fit other models as well.

Why Design This?
I recently traveled a few hours by car to my parents home over the holidays, and packed my favorite bluetooth Bone Conductor headphones, only to discover they were damaged in transit. I was able to repair them with Cyanoacrylate glue (aka "SuperGlue"), but this experience highlighted a need for a 3D Printed Protective Case for my bone conductor headphones.

Bone Conductor Model
I purchased my Bone Conductor headphones from Amazon for $140: NANK Runner Diver2 Bone Conduction Headphones (IP68 Swimming Headphones with MP3 Player Built-in 32G Memory, Bluetooth 5.3 Open Ear Headphones with CVC6.0).

3D Scanner Was Used
I used the Einscan SP 3D scanner to create a 3D image of the head phones, and then designed a hinged case with snap detail to hold the headphones.

Hinge Details
The hinge is made with 3 connecting pieces that attach to both halves of the carrying case via 2 hinge pins that are a common construction nail, cut to length.

Snap Closure Design
There is a snap-detail in 2 locations on the top and bottom of the carrying case, that keeps it safely closed while protecting your bone conducting headphones.

3D Printed on a Prusa i3 MK3s with PETG filament, 0.4mm nozzle, 0.2mm layer height, 3 perimeters, 4 solid bottom layers, and 5 solid top layers.

Assembly Instructions
Assemble with 2 construction nails, cut to length. Place the cover on the case, assemble the 3 smaller hinge pieces, and slide 2 nails through the hinge holes. Hinge is designed with clearance for the nails. Then use a pliers to force the small ring onto the end of the nail; the ring is an interference fit, designed to grip tightly to the nail, and preserve the hinge integrity.