The Project Omega Headphones were a several-year long project by the creator, known as DMS, to create a "love letter to audio." The result is a lovely, lightweight, and very competent pair of headphones. After coming across the project, and finding out that the design would be open-sourced after a year of selling them as a product, I decided that I would build some once they were released.

I decided to build two pairs, one for a friend as a birthday present, and one for myself. This allowed for several benefits - I was able to do some minimal driver matching, as well as print and process parts in larger batches. The Project Omegas are just the cups though, which meant I had to find a headband to mount them on. The official project used an off the shelf design the creator licensed, but I wanted to evaluate options I could produce with my own equipment. This led to finding Capra Audio, who publishes all their designs under a Creative Commons license. They have a headband that I was skeptical about, since it is entirely 3D printed. From my observation, there is a bit of a "when all you have is a hammer, everything looks like a nail" mentaility in the 3D printing community, leading to designs that could have easily used off the shelf components or another small-scale manufacturing technique - as it turns out, the Capra Headband is not one of them. It is incredibly well designed, comfortable, and overall something I would recommend. There exists a set of straps that are replacements for the stock straps on other headphones, which I would also highly recommend if you can print TPU and have a supported headphone.

After printing far too many test pieces to decide what materials I wanted to use, I settled on the following:

• Project Omega Cups: Sparta3D Chameleon ASA, specifically Burnt Titanium and Abyss Purple
• Headband flex parts: Black Polymaker 95A TPU
• All other printed parts: Annealed Phaetus Black PET-GF, wet sanded and polyurathane coated

I also decided to vapor smooth the ASA cups, because it dramatically changes the look of the Chameleon ASA in a way that I really like. That filament is a huge pain to print, and has notably poor layer adhesion, but I couldn't resist using it on this project once I discovered how it looked.

Anyhow, here is the pair I made for myself in Abyss Purple:

They even got a cameo in DMS's 2026 NYC CanJam video!