To practice surface modeling techniques, I challenged myself to create a 1:1 (or as close as I could) model of my Sony WH-1000XM4 headphones in SOLIDWORKS. I wear these headphones a lot, but never realized how complex and intricate the geometry and curves are until I set out to model it.Â
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I used a reference photo I found online, and scaled it by measuring points on my pair of headphones. I then created a master surface model to keep consistent geometry and clean references for each of the parts, which allowed for ease of adjusting fine dimensions towards the end.
Using symmetry to my advantage, I modeled a quarter of the headband, and only one of the earcups, and mirrored the parts across before adding additional details.
Smooth complex surfaces were achieved using surface lofts, adding plenty of guide curves based on reference images and end constraints.
As I was modeling each of the parts, I was considering how they moved in the physical model, and how the physical hinges and constraints would translate to mates. I added mating planes and axes to keep parts in order, which allowed my model to replicate the motion of my physical headphones
A mating axis used for the lower headphone band movement.
They move exactly like the real thing. Shown above as folded to fit into the carrying case.
SOLIDWORKS display settings allowed for some cool visualizations, highlighting internal features and fine details, perfect for a user manual or technical document.
I utilized many split lines to allow for multiple materials per surface, so that I could add additional details like the earcup labelling, button labels, and branding.
Adding embossed details like the buttons and brand text, very rewarding as the model came to completion.
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