Build Your Own 3D Printed Bluetooth Headphones

A few years back, [Shannon Ley] wondered how hard it would be to build a pair of Bluetooth headphones from scratch. Today, we have our answer. The Homebrew Headphones website is devoted to just one thing: explaining how you can use common components and some 3D printed parts to build an impressively comprehensive pair of wireless headphones for around $50 USD.

The headphones pair a CSR8645 Bluetooth audio receiver with a TP4056 USB-C charging module, a 500 mAh LiPo pouch battery, a pair of Dayton Audio CE38MB-32 drivers, and replacement ear covers designed for the Bose QuietComfort QC15. Some perfboard, a couple buttons, a resistor, and an LED round out the parts list.

All of the components fit nicely into the meticulously designed 3D printed frame, and assembly is made as simple as possible thanks to an excellent step-by-step guide. It’s all so well documented that anyone with even basic soldering experience should be able to piece it together without too much fuss.

Of course, these aren’t the first 3D printed headphones we’ve ever seen. But the quality of the documentation and attention to detail really make these stand out.

Nokia 5110 Gets Android Stowaway And A Keyboard

Even though Nokia is largely an afterthought in the phone market now, there was a time when their products represented the state-of-the-art in mobile devices. Some of the their handsets even featured slide-out keyboards and the ability to sent emails; largely unheard of for a device from the late 90s. [befinitiv] was a kid back then and couldn’t afford one of these revolutionary devices, so he built his own modern version that still looks and feels like the original.

To do this he borrowed the case and structure of a Nokia 5110 phone, but modified it to hold a small Android device in the old battery compartment along with a tiny Bluetooth keyboard (which was also built from scratch by [befinitiv]) that connects to the Android phone to mimic the old slide-out style. This isn’t just a case mod, though. He also reverse-engineered the original PCB of the phone and included a Bluetooth module there as well, which allows the phone’s screen and keypad to work mostly as originally intended.

This project goes pretty far to scratch the 90s phone nostalgia itch while still being largely usable as a real phone in the modern world. Assuming you aren’t too hung up on the literal phone aspect, the Notkia project is also an impressive effort to bring new life to these old handsets.

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Headphones described in article, charging off a powerbank through an orange USB cable

Headphone Cable Trouble Inspires Bluetooth Conversion

[adblu] encountered the ever-present headphone problem with their Sennheiser Urbanite headphones – the cable broke. These headphones are decent, and despite the cable troubles, worth giving a new life to. Cable replacement is always an option, but [adblu] decided to see – what would it take to make these headphones wireless? And while they’re at it, just how much battery life could they get?

Armed with a CSR8635 Bluetooth audio receiver breakout module and a TP4056 charger, [adblu] went on rewiring the headphone internals. The CSR8635 already has a speaker amplifier inside, so connecting the headphones’ speakers didn’t require much effort – apart from general soldering difficulties, as [adblu]’s soldering iron was too large for the small pads on the BT module. They also found a 2400mAh battery, and fit it inside the headphone body after generous amounts of dremel work.

The result didn’t disappoint – not only does everything fit inside the headphone body, the headphones also provided 165 hours of music playback at varying volume. Electronics-wise, it really is that easy to retrofit your headphones with Bluetooth, but you can always go the extra mile and design an intricate set of custom PCBs! If firmware hacks are more to your liking, you can use a CSR8645 module for your build and then mod its firmware.

Bluetooth 8-Track Adapters Are A Thing

When it comes to classic cars, the entertainment options can be limited. You’re often stuck with an old cassette deck and AM/FM radio, or you can swap it out for some hideous flashy modern head unit. [Jim] had a working 8-track deck in his Corvette, and didn’t want to swap it out. Thus, he set about building himself a simple Bluetooth to 8-track adapter.

The hack is straightforward, with [Jim] grabbing a Bluetooth-to-cassette adapter off the shelf. These simply take in audio over Bluetooth, and pipe the analog audio out to a magnetic head, which is largely similar to the head that reads the cassette. Pumping the audio to the magnetic coils in the adapter’s head creates a changing magnetic field essentially the same as the audio tape moving past the cassette reader head. It doesn’t really matter whether you’re working with an 8-track player or a regular cassette. Get the magnetic field in the right spot, and it’ll work.

The electronics from the cassette adapter are simply placed inside an old 8-track tape, with holes cut in the chassis for the charge port and on switch. Then, all you need to do is pop the adapter into the 8-track deck, pair with it over Bluetooth, and you can get the tunes pumping.

Others have had success with hilarious Rube Goldberg methods, too. [Techmoan] took a classic cassette-to-8-track adapter, which is actually self-powered by the deck, and simply popped a Bluetooth cassette inside. That worked surprisingly well, and it was interesting to see how it all worked on the inside. We even saw a 3D-printed device on TikTok.

Thus, if you’ve got an old Corvette, particularly of that era with the Doug Nash 4+3 transmission, this might just be the hack for you. Alternatively, you can hack Bluetooth in to just about any classic stereo; we’ve got a guide on how to do just that. Video after the break.

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The speaker PCB inside of the speaker, with a flash chip ZIF holder soldered to the SPI flash pads on the PCB

Bluetooth Speaker Domesticated Through Firmware Mod

This might sound like a familiar problem – you get a Bluetooth speaker, and it sounds nice, but it also emits all kinds of weird sounds every now and then. [Oleg Kutkov] got himself a Sven PS460 speaker with FM radio functionality, but didn’t like that the “power on” sound was persistently loud with no respect for the volume setting, and the low battery notification sounds were bothersome. So, he disassembled the speaker, located a flash chip next to the processor, and started hacking.

Using a TL866 and minipro software, he dumped the firmware, and started probing it with binwalk. The default set of options didn’t show anything interesting, but he decided to look for sound file signatures specifically, and successfully found a collection of MP3 files! Proper extraction of these was a bit tricky, but he figured out how to get them out, and loaded the entire assortment into Audacity.

From there, he decided to merely make the annoying sounds quieter – negating the “no respect for the volume setting” aspect somewhat. After he exported the sound pack out of Audacity, the file became noticeably smaller, so he zero-padded it, and finally inserted it back into the firmware. Testing revealed that it worked just as intended! As a bonus, he replaced the “battery low” indicator sound with something that most of us would appreciate. Check out the demo video at the end of his write-up.

Domesticating your Bluetooth speakers tends to be called for. If you can’t do that for whatever reason, you can rebuild them into an audio receiver – or perhaps, build your own Bluetooth speakers, with aesthetics included and annoyance omitted from the start.

A small round NRF51822 board glued to the underside of a mailbox lid, with a small vibration sensor attached

Check Your Mailbox Using The AirTag Infrastructure

When a company creates an infrastructure of devices, we sometimes subvert this infrastructure and use it to solve tricky problems. For example, here’s a question that many a hacker has pondered – how do you detect when someone puts mail into your mailbox? Depending on the availability of power and wireless/wired connectivity options, this problem can range from “very easy” to “impractical to solve”. [dakhnod] just made this problem trivial for the vast majority of hackers, with the FakeTag project – piggybacking off the Apple’s AirTag infrastructure.

This project uses a cheap generic CR2032-powered NRF51822 board, sending the mailbox status over the FindMy system Apple has built for the AirTag devices. For the incoming mail detection, he uses a simple vibration sensor, glued to the flap lid – we imagine that, for flap-less mailboxes, an optical sensor or a different kind of mechanical sensor could be used instead. Every time someone with a FindMy-friendly iPhone passes by [dakhnod]’s mailbox, he gets an update on its status, with a counter of times the sensor has been triggered. [dakhnod] estimates that the device could run for up to a year on a single battery.

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Summer’s Coming – Let Mowerino Cut Your Grass

In the Northern hemisphere, summer is about to hit us full bore. While we love the season, we do dislike lawn maintenance. Apparently, so does [salmec] who developed the Mowerino around an Arduino Mega 2560 board.

As you might expect, the robot uses sharp blades so, you probably want to be careful. There are sensors that allow the machine to self-navigate or you can control it via Bluetooth. This is one of those things that seems easy until you try to actually do it. Nylon trimmer string is probably safer, but it breaks and it is hard to keep it cutting. Blades are more robust but also riskier to things like rocks, fingers, and pets.

Moving around in the yard is also an issue. The Mowerino has some ordinary-looking caster wheels in the front. That might be a place for improvement since most yards are not friendly to that kind of wheel. The other thing we worried about is what happens to the grass clippings. Around here, a week of rain means your mower will choke on grass clippings. On the other hand, the Mowerino has a smaller blade so maybe that helps mitigate clipping clogging.

Overall, though, it looks like it might be a good place to start if you dream of robot groundskeepers patrolling your estate. Most of the mowers we see like this have big wheels. But, of course, not all of them.

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