Corsair Virtuoso Suspension Headband by yaikou

Last crawled date: 2 years, 10 months ago

Corsair's Virtuoso headset is an amazing piece of kit, and the microphone is one of, if not the, best on the market for a headset. While I love most things about the Corsair Virtuoso headset, there are a couple minor things I wanted changed: earpads and headband.
For the earpads, I picked some up from a third-party on Amazon - https://www.amazon.com/gp/product/B08HXVD5RJ
For the headband, it's much more involved, and requires some irreversible destruction to the cloth and padding. Because I don't want to be held liable for any damage done to your headset, I will omit the process of disassembly. Do this mod at your own risk!
I printed this in polycarbonate, but any filament with strong layer adhesion will work, such as PETG or PCTG.
Supports for the earcup mount will need to be printed, and you'll need to be patient with clearing out the supports.
The mounting tabs are the weak points in this design, so if you have an extremely large head, this may not work for you. please understand the risks involved before proceeding with this modification. A stiffer material like PLA could be suitable, but I worry about the brittle nature of that. Thus far, everything has been printed in PC and is working well.
BOM:
1x Corsair Virtuoso (Base or SE)
1x SteelSeries Arctis 7 elastic band (https://www.amazon.com/gp/product/B08RHK2ZMK)
8x 4mm M3 countersunk screws
2x 6mm M3 countersunk screws
10x M3 nuts
1x hook and loop cable tie, cut to between 25-30mm
Printing:
Use supports for all components (everywhere)
Print headband on its sid
Print earcup mount with the single hex deboss flat on the bed
Print tab with flat side on bed
Assembly:
Screw tab to earcup with original headset screws
Lay wires in tab channel
Slide cover over tab and exposed mounting hardware and affix with original screws
Slide opposing cover over the other side of the tab, carefully pulling the wires through with it
Insert tab in earcup mount
Affix with 6mm M3 screw and nut
Affix headband to that assembly with four (4) M3 screws and nuts
Repeat process for other side
Using the hook and loop cable tie, attach headset wires to the holes in the top-middle band
Thread elastic headband through and connect it to itself
ENJOY! :)
Changes I may make in the future:
Simpler, easier to post-process design
Add various widths of headband
Modify design to use original metal earcup tabs