V3
The V3 is the most advanced and most complex LTS design to date, a result of several previous headphone concepts combined into one during a three year long development process. It's an advanced headphone, both in concept and execution, featuring several unique design solutions, constructed out of the most modern materials available, and utilizing cutting edge additive manufacturing technologies previously unseen in the headphone industry. Since the very beginning of the development, the main goal has been to create a flexible high-end headphone, not acting only as a high quality standalone product, but also as a fully modular DIY platform, enabling owners full freedom to build, assemble, disassemble, test, experiment and customize their headphone in aesthetic, as well as functional aspects. The idea is to offer as much flexibility and freedom to headphone builders as possible, similar to the flexibility custom PC builders or DIY speaker builders have had for years, but at the same time without sacrificing any of the things necessary to satisfy those who just want to purchase and own a great headphone that's already been custom built for them. Designed to be a rugged and tough headphone that will last for years, it's not only built out of tough materials, such as the Carbon Fiber reinforced polyamide and CNC machined aluminium, it's also designed in a way that enables every single component to be replaced if necessary, prolonging the life of the headphone. Despite being tough, it still features an elegant and understated appearance, combining function with form, without sacrificing either. The outer CF PA or aluminium frames surrounding the ear cups provide impact protection and improve the rigidity of the whole assembly, the large tuning ports on the ear cups offer a great sense of openness and enable a wide range of sound customization, while the fully opened driver chambers completely isolate the rest of the headphone from the sound-waves emitted by the rear side of the driver. This last aspect is also the main functional differentiator between the V2 and the V3, with the V2 featuring a more classical opened ear cup design. Each concept has pros and cons that come down to personal sound preferences. Internally, the headphone has been designed to accept a wide range of drivers, featuring replaceable driver holder components, removable ear pad rings, as well as unique filter frame components, enabling simple and quick customization of the headphone's sound character depending on one's personal taste, as well as adapting it for use with various driver and ear pad combinations. It also shares the basic geometry, the headband assembly, hinges and frames with the V2 model, meaning that they're both virtually identical in terms of feel, fit and wearing comfort.
The V3 will be available in several versions of DIY kits at various price points, as well as custom headphones, fully built according to the customers specifications and featuring only the best components. Make no mistake though, in case you do change your mind about modding or customizing your headphones in the future, you will still be able to do it just as easily as someone who initially purchased a DIY kit and built the headphone on their own. Furthermore, if you initially decide to go for the less expensive options and stick to 3D printed components instead of CNC machined ones, you will still be able to upgrade to CNC machined components in the future without any issues.
The V3 will be available in several versions of DIY kits at various price points, as well as custom headphones, fully built according to the customers specifications and featuring only the best components. Make no mistake though, in case you do change your mind about modding or customizing your headphones in the future, you will still be able to do it just as easily as someone who initially purchased a DIY kit and built the headphone on their own. Furthermore, if you initially decide to go for the less expensive options and stick to 3D printed components instead of CNC machined ones, you will still be able to upgrade to CNC machined components in the future without any issues.
KEY FEATURES
- Unique layered and fully modular V3 ear cup design, allowing for reversible and simple modding and customization.
- Utilization of the most advanced additive manufacturing methods and materials previously unseen in the headphone industry.
- Extremely solid ear cup assembly method, featuring ten Swiss made brass threaded inserts and stainless steel fasteners.
- Simple disassembly and assembly of the entire headphone using basic tools.
- Certain components designed to follow both CNC machining, as well as additive manufacturing requirements.
- Multiple materials and manufacturing methods available for certain components, allowing for flexible headphone production at several price points.
- Hinge yokes and frames available in CNC machined aluminium or Carbon Fiber reinforced polyamide, both with multiple post-processing options.
- Replaceable filter frame components, available in multiple shapes, thicknesses and with various acoustic impedance properties.
- Extremely rigid baffles and filter frames manufactured out of a high quality Graphite reinforced polyamide using highly advanced SLS technology.
- Ear cup shells manufactured out of very impact resistant and durable PA12 plastic using highly advanced HP Multi-Jet Fusion technology.
- Replaceable driver holder components, manufactured out of Carbon Fiber reinforced polyamide, the strongest and most rigid SLS AM material.
- Drivers angled at 18 degrees, with a forward offset, for a more natural sound presentation and improved imaging.
- Adjustable driver-to-ear distance using spacing adapters in combination with already mentioned driver holders available in several versions.
- Compatible with multiple 46 mm diameter drivers, while custom driver holders can be developed for virtually any driver up to 50 mm in diameter.
- Adapters for drivers with diameters below 46 mm will be developed and compatible with the basic baffle designs.
- SLS manufactured ear pad rings for simple twist-locking ear pad attachment, compatible with most ~100mm diameter ear pads.
- High quality Hirose cable connectors for simple headphone cable removal and replacement.
- Will be available as kits serving as excellent DIY and modding platforms for owners who would like to build their own headphone to their liking.
- Will be available in hand-built versions with custom post-processing and finishing options.
- Will be shipped in high quality, foam padded, aluminium cases.
V3 RENDER GALLERY
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DESIGN HIGHLIGHTS & GOALS
The V2 and V3 headphone models share most of the design highlights and goals, but with slightly different approaches. As already mentioned previously, the V2 is a more traditional open-backed headphone with a single rear acoustic chamber, while the V3 has a separate chamber behind the driver, completely isolated from the baffle tuning ports. This gives each model slightly different acoustic characteristics and allows for slightly different tuning options. Most of the goals regarding the build quality, materials used, manufacturing methods utilized, drivers and ear pads used, as well as the tuning and modding freedom, apply to both models.
All of these features leave pretty much an endless ability for tuning the sound, and because the plastic components themselves are so incredibly rigid and acoustically neutral, it's not very difficult to find a proper balance with any combination of drivers and ear pads.
- Ability to manufacture headphone components out of various materials using various manufacturing methods at different price points, which means that certain components had to be designed in a way that enables utilization of both additive manufacturing and CNC machining. This enables the same headphone designs to be used for building headphones at various price points.
- A layered, fully modular ear cup has been developed for the V3 model, meaning that all of the main components are precisely layered on top of each other, with their entire complex three-dimensional surfaces being in full contact with matching surfaces on adjacent components, which is more difficult to achieve than it may seem at first. Usually two complex components are connected to each other through flat contact surfaces, most commonly around fastener holes, but connecting two three-dimensional shapes together and making them fit like a hand inside a glove requires a far more elaborate and complex design, as well as incredible levels of dimensional accuracy, which the SLS printing technology is capable of achieving. In addition, all the fasteners go through all of the components at once, holding the driver holder, filter frame and the baffle in place by attaching to the brass threaded inserts on the ear cup shell. This method enables all of the individual components to form a layered system so rigid that it acts as a single solid unit when assembled, while still being easily disassembled if necessary. This is precisely what the goal of the design was all along. To create a modular ear cup that consists of multiple individual components that can be easily replaced or upgraded at any moment, but form an incredibly solid assembly, with no unwanted creaks, rattles, gaps between components, etc.
- Ability to accept various drivers from a wide price and performance range for simple future upgrades and a great modding potential. This meant that the headphone had to have a simple, but very solid and durable method of attaching the drivers of various diameters and thicknesses onto the baffle, with multiple disassemblies and assemblies possible, and with no risk of damage to the drivers or the headphone components. A unique driver holder component had to be developed, and it was made possible due to the Carbon Fiber reinforced polyamide and SLS printing technology, which enabled the production of a very compact, but extremely strong and rigid part. It was crucial to make the driver holder component as small as possible, in order for it to be as acoustically neutral as possible, while also leaving enough room to maximize the size of tuning ports on the filter frame and baffle components.
- Ability to reversibly adjust the acoustic impedance of the baffle, as well as the size and shape of the enclosed ear pad volume has been one of the primary design goals since the very beginning of the V2 and the V3 development, as those aspects are crucial for fine tuning the sound, especially on headphones meant to serve as modding platforms, with multiple drivers available for potential use, each with slightly different requirements. These adjustments are possible thanks to the implementation of filter frames, unique components not found on other headphones, which are a result of the layered baffle design, and enable quick, easy and fully reversible modifications to the acoustic chamber between the ear and the driver. They can be printed in several versions, with varying thicknesses and varying concave shapes, enabling a high degree of freedom for manipulating the acoustic characteristics of the headphone. The thickness of the filter frame will determine the enclosed ear pad volume, primarily impacting the low frequency performance, while modifying the concave shape of the component has several effects on the mid and high frequency performance. The shapes and sizes of tuning ports can also be redesigned if necessary, and the filter frames themselves can be covered with various sound damping or absorbing materials. The tuning ports on the filter frames are covered with acoustic mesh filters specifically made for use with headphones and microphones. It's important not to mistake acoustic mesh for felt or paper filters usually used on more affordable headphones, as acoustic mesh filters are made out of special polyester blends, with very consistent mesh opening sizes, and a far more linear effect on the sound of the headphone. They enable exceptionally accurate and consistent control of acoustic flow through the tuning ports, and are available in a wide range of mesh densities, each with different acoustic impedance characteristics. The biggest advantage of acoustic mesh filters over any other method of controlling acoustic flow is the fact that they can provide a high degree of acoustic impedance, but with very little reflection of sound waves. In order to fully utilize this property, the default tuning ports covered by the acoustic mesh have been designed to be as large as possible. Having bigger tuning ports covered in high impedance mesh filters also leaves less solid plastic areas on the baffle, areas that can reflect sound and cause resonances. Having smaller tuning ports with more transparent mesh filters, or nothing covering the ports at all, could in theory lead to the same overall acoustic impedance of the baffle, but with a much larger degree of sound reflection due to larger solid, plastic areas. On top of that, larger tuning ports increase the subjective sense of openness while wearing and listening to the headphones. The choice of acoustic mesh has a massive impact on the sound of the headphone, especially in the low frequencies. A more dense, less acoustically transparent mesh will increase the low frequency SPL, thus increasing the bass response, while a more transparent mesh will decrease it. In a way, the acoustic mesh acts very similar to a high-pass filter with a cut off frequency of around 1000 Hz, gradually increasing its impact on the sound of the headphone as the frequency is lowered. The effects across the affected part of the frequency range are linear and very predictable. Therefore, simply swapping the acoustic mesh, while keeping the same filter frame design, enables very precise control of the headphone bass response by changing the overall tilt of the frequency response below 1000 Hz. On the other hand, the peak of the low frequency response can be lowered by reducing the enclosed ear pad volume through the use of a thicker filter frame, and vice versa. In addition to that, an "air damping" system via tuning ports can be established as well. That means that a pair of acoustic meshes is glued onto both sides of the frame filter, with a 2-3 mm gap between the two mesh filters, creating a small air chamber that acts as an additional dampener. That's because the top mesh filter has a lesser acoustic impedance than the bottom one, which causes the acoustic pressure built up in the enclosed ear pad volume to be vented out more gradually, allowing for even more precise and fine bass response tuning options. For all of those reasons, a lot of care has been put into designing the default filter frame components and finding a range of acoustic mesh filters appropriate for the drivers used during the V2 and V3 development, establishing solid base configurations which can then be fine tuned by using slightly modified versions of the filter frame components or by using different acoustic mesh filters, depending on the specific driver requirements and personal sound preferences. Using such simple, affordable and replaceable filter frame components means it's very easy to reversibly change the sound character of the headphone, while also having the ability to configure the headphone for use with entirely different drivers, without having to change the basic structure of the headphone in any way. Because of this, the potential lifetime of a headphone is prolonged as well, and in the long run it's more efficient to modify it rather than to buy an entire new headphone.
- Removable ear pads - Ear pads are one of the crucial elements that determine the sound of the headphone. They're available in various sizes, thicknesses, internal and external diameters, and they're made out of various types of foams and materials covering them. Each and every one of those aspects has a massive impact on the sound of the headphone, which is why picking the right ear pads is one of the most important steps in the headphone sound tuning process, but also one of the most quick and easy ways to slightly change the sound character of the headphone. This is why developing a quick and easy method to attach and detach ear pads was one of the main design goals during V3 headphone development. Ear pad attachment rings were the obvious choice for this purpose. They're quite simple components, 3D printed out of very flexible and durable PA11 plastic using SLS technology, and they attach onto the headphone baffle via six L-shaped clips and a twist-locking mechanism. The default attachment rings are specifically designed for 100 mm diameter ear pads, meaning there's a wide variety of compatible models available from OEM's and aftermarket sources. I've tested a lot of them during V2 and V3 development and found a couple of favorites which performed well both in terms of sound and in terms of comfort, although I do plan to design and make custom LTS ear pads in the future.
- Ability to adjust the driver position has been another crucial design goal of the V2 and the V3 headphone models, closely tied together to the rest of the customization features mentioned already. How close the driver is to the ear has a slight impact on several aspects of the sound, and having the ability to fine tune that is not only unique in the headphone world, but also crucial in getting the best performance out of each driver and each headphone configuration. Not only because each driver has a slightly different ideal distance-to-ear value, but also because this system enables more customization depending on personal preferences. Some people might like the slightly more forward and aggressive sound when the driver is closer to their ear, others might prefer the driver placed slightly further away, for a more relaxed presentation. All of this is possible thanks to SLS manufacturing of cheap, but extremely strong and rigid driver holder components which will be available in a wide range of models, designed for various driver-to-ear distances, as well as various driver diameters and thicknesses.
- Ability to tune the acoustic characteristics of the chamber behind the driver allows for additional sound tuning options through the application of various acoustic mesh filters, felts or fabrics covering the rear grill and controlling its transparency. The chamber walls can be lined with sound absorbing materials, while the volume of the chamber can be filled with various foams or speaker cabinet sound damping materials, such as Polyfill. The walls of the chamber are asymmetrical and the shape of the chamber is irregular, while the rear face of the driver is at a slight angle relative to the grill, which slightly reduces resonances compared to a perfectly cylindrical chamber as well.
All of these features leave pretty much an endless ability for tuning the sound, and because the plastic components themselves are so incredibly rigid and acoustically neutral, it's not very difficult to find a proper balance with any combination of drivers and ear pads.
FILTER FRAMES
A simplified example showing how various acoustic mesh filters affect the sound of the headphone. A higher density acoustic mesh with a higher level of acoustic impedance will increase the low frequency SPL, while a lower density acoustic mesh with a lower level of acoustic impedance will reduce the low frequency SPL. Frequencies above approximately 1000 Hz are mostly unaffected, so the method of swapping filter frames with various acoustic mesh fabrics attached onto them is a great way to fine tune the low frequency performance of the headphone, regardless of the drivers used. Please note that there are a lot more than three types of acoustic mesh materials available, with much finer differences between them than shown in this example. The effects of acoustic mesh filters are very predictable across the frequency range that they affect, without introducing any peaks or dips into the frequency response, while their effect becomes gradually more pronounced towards the lower end of the frequency range. As already mentioned previously, reducing or increasing the frequency peak of the bass response can be done by using thicker or thinner versions of the filter frames in order to reduce or increase the enclosed ear pad volume.
It's a unique and excellent way to modify a headphone to ones personal liking, whether to change the sound character while keeping the same driver, or in order to adapt the headphone to work with a different set of drivers. In either case, the rest of the headphone doesn't have to be changed, which means that achieving a different sound character is far more affordable than buying an entire new headphone.
It's a unique and excellent way to modify a headphone to ones personal liking, whether to change the sound character while keeping the same driver, or in order to adapt the headphone to work with a different set of drivers. In either case, the rest of the headphone doesn't have to be changed, which means that achieving a different sound character is far more affordable than buying an entire new headphone.
TRANSITION FROM THE v.0.9 TO THE PRE-PRODUCTION MODEL
While working on the v.0.9 and the prototypes leading up to it, I mostly focused on mechanical, ergonomic, functional and visual aspects of the headphone, trying to establish a strong base to work from towards meeting all of the future development goals. On the other hand, during the transition from v.0.9 to the final pre-production design, I focused on the acoustic aspects of the headphone far more. This phase stretched over a period of over two years, because I was only able to work on the headphone during my free time and while not being too busy at the university. On top of that, I've been working on several other headphone models at the same time as well. However, during these two years, a lot of changes have been made to the headphone design, some minor and some major, but most of them were a result of countless hours of listening and testing of various headphone drivers, ear pads, acoustic mesh filters, as well as various combinations of different acoustic treatments. This has led to a lot of incremental changes and improvements to the headphone components, until the final pre-production version of the design has finally been reached. Most of the major changes and differences between the v.0.9 prototype and the latest version are functional in nature and located below the surface, with the external appearance of the headphone going through minor changes only. It's important to mention that acoustic performance of the pre-production version of the headphone is significantly superior to the v.0.9, despite looking very similar to the old version after a quick glance. The same is true for mechanical aspects of the headphone as well, such as the more refined operation of all hinges, a higher quality headband adjustment mechanism, and the general improved sense of solidity due to even tighter assembly tolerances than before.
Another major change is the planned utilization of CNC machining for several mechanical components of the headphone, which will enable production of the hinge yokes, frames, headband pieces, sliders and grill rings out of aluminium, further improving the quality of the headphone. These components have been redesigned according to all specifications and design rules of CNC machining. This means they can easily be CNC machined, but at the same time, they can still be produced using additive manufacturing technologies as well, which widens the production possibilities and will enable the production of this headphone at several price points.
It's very important to note that CNC machining the components is vastly more expensive than producing them using additive manufacturing technologies when producing them in small quantities. For example, CNC machining a single unit of the hinge yoke out of 7075 aluminium costs approximately 15x more than 3D printing it out of Carbon Fiber reinforced polyamide using SLS technology. However, as the production quantity goes up, price per unit of CNC machined components goes down by an incredible amount, to such an extent that CNC machining 50 units of the hinge yoke makes each unit only about 30% more expensive than 3D printing it. These production cost dynamics mean that CNC machining is perfectly viable in case of higher volume production, and given enough interest and demand for the headphone, it will surely be utilized in its production.
Another major change is the planned utilization of CNC machining for several mechanical components of the headphone, which will enable production of the hinge yokes, frames, headband pieces, sliders and grill rings out of aluminium, further improving the quality of the headphone. These components have been redesigned according to all specifications and design rules of CNC machining. This means they can easily be CNC machined, but at the same time, they can still be produced using additive manufacturing technologies as well, which widens the production possibilities and will enable the production of this headphone at several price points.
It's very important to note that CNC machining the components is vastly more expensive than producing them using additive manufacturing technologies when producing them in small quantities. For example, CNC machining a single unit of the hinge yoke out of 7075 aluminium costs approximately 15x more than 3D printing it out of Carbon Fiber reinforced polyamide using SLS technology. However, as the production quantity goes up, price per unit of CNC machined components goes down by an incredible amount, to such an extent that CNC machining 50 units of the hinge yoke makes each unit only about 30% more expensive than 3D printing it. These production cost dynamics mean that CNC machining is perfectly viable in case of higher volume production, and given enough interest and demand for the headphone, it will surely be utilized in its production.
LATEST PRE-PRODUCTION DESIGN CHANGES
This is a list of the most important specific changes and improvements that have taken place during a two year long transition period from the v.0.9 prototype to the pre-production version of the headphone.
- Diameter of the ear cup and baffle has been slightly increased compared to the v.0.9, while thickness of the hinge yokes and frames has been reduced by the same amount, resulting in a more pleasing appearance and improved headphone proportions.
- Hinge yokes and frames have been redesigned, featuring a more elegant appearance, while also being suited for CNC machining. The rotating hinge connecting the yoke to the headband slider has also been completely redesigned and significantly strengthened, featuring a custom CNC machined 4 mm diameter stainless steel fastener and a new rotation stop system. Special damping grease will also be used on the hinges, giving them a silky smooth feel similar to that found on high-end volume pots.
- Hinge attachment components have been redesigned and significantly strengthened.
- Headband sliders have been redesigned as well, now featuring an oval cross-section instead of a round one, as well as featuring a new rotation stop mechanism matching the redesigned hinge yokes.
- Headband pieces have been completely redesigned, featuring a more elegant appearance, while also being better suited for CNC machining. This will widen the manufacturing options available for V1, V2 and V3 headphones, all of which feature the same new headband design. Headband adjustment mechanism geometry is identical to that on the older headband version.
- The default position of the headphone driver has been slightly changed based on listening test results, in multiple small increments, by gradually offsetting it towards the middle of the baffle, bringing it slightly closer to the ear, while also slightly reducing the driver angle. These changes led to improvements in imaging and a stronger sense of frontal sound projection regardless of headphone drivers used.
- The driver holder component has been redesigned accordingly, now featuring a slightly more rigid design that secures the driver in place more effectively, while also being more acoustically neutral due to it's shape.
- The size and shape of the enclosed ear pad volume has been changed by redesigning the baffle on the ear side, with the depth of the baffle reduced and the concave shape being less pronounced than before. This has led to multiple acoustic benefits, including flattening the frequency response, reducing dips and peaks between 3000 and 6000 Hz and improving bass extension. These changes were noticed regardless of drivers and ear pads used.
- Baffle and frame filter tuning ports have been redesigned as well, with the ports now being 3-dimensional in shape and 30% larger than before, which means the baffles are more opened, in turn meaning that acoustic mesh filters are more efficient because the area they cover is larger than before. In addition, because the baffle has less solid plastic area now, sound reflections and resonances inside the enclosed ear pad volume have been significantly reduced, while also resulting in a more airy and opened feel while wearing and listening to the headphones.
- Filter frame components have been additionally redesigned and now feature an improved attachment mechanism, with a special lip designed to tuck under the driver holder component, improving the seal between the filter frame and the baffle, while also making the entire assembly more rigid.
- Ear pad attachment rings have been redesigned, with the old magnet attachment system replaced with a twist-locking mechanism that eliminates the need to use 24 magnets per headphone. However, the decision is not yet final because the magnet attachment system is still more elegant to use and potentially more durable as well. Multiple versions of ear pad attachment rings will be developed for multiple ear pads available on the market.
- A new additive manufacturing method became available, HP's Multi-Jet Fusion, which enables production of end-use PA12 parts that require no further post-processing after manufacturing. Because the surface finish on MJF manufactured parts is very attractive straight out of the machine, featuring a matte black surface with a fine texture, exactly what I've planned for the V3 headphone ear cups in the first place, I've decided to utilize this new technology and material for the ear cup shell production. The ear cup shells have also been slightly redesigned for a more elegant appearance, with the grill openings slightly enlarged as well, in order to match the new baffle design. Several weight saving measures have been taken as well by integrating multiple ribs and removing excess material on the underside of the component, increasing the shell rigidity and reducing its weight by approximately 15%. The MJF PA12 material is also incredibly impact and wear resistant, which makes it ideal for the outer shell as it won't get damaged easily. The baffle and filter frame will still be manufactured out of Graphite reinforced polyamide.