Fiio FT1 Hinge Replacement

I love these headphones, but my big head keeps breaking the hinge area that holds the head band to the arms that hold the cans. Thankfully as I have found out, because Fiio has opted to just have the cans feed directly into a cable instead of wrapping through the headband, these are also very repair friendly. So I spent a weekend reverse engineering the hinge area to beef it up and hopefully fix a few of the fail points in the original part. Certain areas are thickened up compared to the original part, which is very svelte and thin. I did introduce some chamfers to the shape to have a nicer hand to it and not have it just be a gigantic sharp edge block. I'm still relatively new to designing things in CAD and respecting tolerances, so the fit is a little tight in areas but you won't need to force anything with unfathomable strength. If you feel too much resistance, double back and check to make sure the parts are fitting together correctly. The headband will probably need to be seated farther into the box than you realize and this will be the main source of frustration when putting it back together. Note: This replacement part reuses all the hardware from the original part, so please make sure you have the 2 plastic balls, 2 springs, and 5 screws for each side to put this together. Label is optional and I provided a recess to put the label on and hide the screw that comes in from the outside. For the pictures posted the main box was printed in PLA, with the cover printed in PETG for strength. If I find later that the box cracks or undergoes any sort of failure I'll likely print its replacement out of PETG, so please be aware of that. These should not have to be printed with any supports, the box though will need to be reoriented so it sits up on its end so the chamfered edge faces up. Print time was tested on an Elegoo Centauri Carbon using stock presets for PETG and PLA, and the average printing time is roughly 1.5 hours to print parts for both sides at once.