I have a steel helmet and have made the armor plates. The camera is going to be 3d printed. For the microphone I've found enough pictures and dimensions to make my own. The only piece left is the ear defender. I really don't want to have to buy a whole kit just for one piece. I'm also trying to do my whole build with what I already have or can make.

I searched for a 3d printable ear defender and didn't like what I found. All of them including paid models are completely misshapen.

Using some pictures I was able to model up the ear defender in Fusion 360. I used a picture of one sitting on a grid cutting mat as a template. With the lighting and being at a bit of an angle the dimensions might be off a bit.

If someone could help out with the dimensions I could make it a little more accurate.

I did a test print of the ear defender. I was pretty happy that it fit the plate that I made. The pad fits over my ear with a little room to spare. The dimensions might be a little off from the real part, but it's a usable size.

Next I modeled up the headset. I found some pictures of one on a grid mat and some dimensions. It's not going to be an exact replica, but it still looks the part.

I used quarter inch break lines for the shaft.

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The impossible takes a while longer and goes over budget too...

From a dimension I could find the shaft should be 5.08mm. I'm using a piece of 5mm round bar.

I printed out the parts and tried it out. The headset is a tight enough fit in the ear defender to stay in place on it's own. I'm going to make some changes to the center piece. Otherwise the rest of the parts turned out fine.

Last year I printed out the parts, but wasn't quite happy with it. For the outer piece I printed with fine layers. After sanding, priming and painting it looked ok. I didn't like that it was smooth. I wanted it to have some texture.

I searched for how to add texture to the model. I gave it a few attempts, but I wasn't turning out how I wanted it to. Maybe with some more practice or trying a different way it would work.

Recently I've been trying out printing with fuzzy skin and was liking the effect. I printed the outer piece at an angle. That allowed the fuzzy skin to be on every surface. The print looked good, so I printed the final one with od green filament.

I finally had a printer that was capable of printing tpu. The pad was printed with 2 shells and 5% gyroid infill. It's a little stiffer than a pad in a hearing defender, but is much better than being plastic.

A piece of t-shirt was glued to the inside of the pad. The shaft is retained with a screw in the bottom. It can easily be adjusted. The rest of the parts were super glued together.

Ooooooh good job. Loving the ' fuzzy skin '