I've had a couple of Bose Aviation X headsets for a number of years.  One headset had chunks of plastic broken out of both yokes (the parts that hold the earcups).  I believe I'm correct in that Bose no longer supports these headsets, and even if they did, they charge a flat fee for repairs that is/was very expensive!  The audio quality of the Bose headsets is unsurpassed, but it is inexcusable that they are so fragile for a $1000+ item!  To add insult to injury, Bose drops support on old headsets as a form of forced obsolescence to induce you to buy the latest/greatest product.

Jon Croke, who produces the Homebuilt HELP video series, recently released a "Tip of the Week" about using 3D printing to very economically produce replacement yokes for the Bose headsets.  I don't have easy access to a 3D printer, but he also mentioned that Ebay replacement yokes were available.  I found a pair of 3D printed yokes, carbon fiber reinforced and with a lifetime guarantee, for less than $40.

I order a pair of these and the quality and strength/durability appears to be excellent!  They look "industrial strength" compared to the original parts and have a nice textured finished on the exterior:

As I removed the original yokes, I gently flexed one of them and it easily cracked:

It took all of 15 minutes to do the repair.  The end result looks great, functions great, and more importantly, appears to be much more durable than the original part:

Thanks to Jon for his great videos and providing alternatives to very expensive repairs - if available at all!



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Yes, as a 3D printer owner I find Thingiverse is great in regards to finding possible solutions. They also have an editor, so if you find a piece that is designed for a completely different purpose, have no 3D design experience but feel that piece can be used in another way, the website customizer will let you manipulate measurements, proportions, etc. to make a new variation of the design. For example, I have seen test tube holders modified to hold large pods for paintball through use of the customizer.

Thanks for this great share John!

 As the proud owner of four of those same model Bose headsets (all of which are currently working well except for one one severed wire, a passenger folded the front seat shut onto the headset cord, sigh) I am delighted to see your information, John. Thanks a lot!



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