Puck
A fully modular, repairable, and customisable headphone system designed to reduce e-waste and put users in control of their tech.
A fully modular, repairable, and customisable headphone system designed to reduce e-waste and put users in control of their tech.
STUDENT WORK
95 - HD
PROJECT TIMELINE
June - Sept 2025
KEY SKILLS
Complex CAD iteration
Complex CAD iteration
Mechanical & modular design
Mechanical & modular design
User-focused design
User-focused design
design for repair
design for repair
Materials engineering
Materials engineering
Visualisation
Visualisation
PROBLEM
Headphones are disposable products. Failure of a single component, be it a battery, hinge, or audio port, renders the entire product useless, resulting in needless waste. Users lack repair confidence, and products offer little opportunity and support.
Headphones are disposable products. Failure of a single component, be it a battery, hinge, or audio port, renders the entire product useless, resulting in needless waste. Users lack repair confidence, and products offer little opportunity and support.
Headphones are disposable products. Failure of a single component, be it a battery, hinge, or audio port, renders the entire product useless, resulting in needless waste. Users lack repair confidence, and products offer little opportunity and support.
SOLUTION
the Puck Headphones are fully modular and user repairable. Every part—PCB, drivers, battery, hinge—is replaceable without the need for specialised tools or technical skill. A removeable “puck” module contains all the complex electronics, and can be easily removed for simple repairs. A system of friction-pins, pogo pins, and USB-C connections makes swapping parts easy. The customisable outer modules snap in via magnetised bayonet mount, allowing users to switch styles or functionality.
the Puck Headphones are fully modular and user repairable. Every part—PCB, drivers, battery, hinge—is replaceable without the need for specialised tools or technical skill. A removeable “puck” module contains all the complex electronics, and can be easily removed for simple repairs. A system of friction-pins, pogo pins, and USB-C connections makes swapping parts easy. The customisable outer modules snap in via magnetised bayonet mount, allowing users to switch styles or functionality.
the Puck Headphones are fully modular and user repairable. Every part—PCB, drivers, battery, hinge—is replaceable without the need for specialised tools or technical skill. A removeable “puck” module contains all the complex electronics, and can be easily removed for simple repairs. A system of friction-pins, pogo pins, and USB-C connections makes swapping parts easy. The customisable outer modules snap in via magnetised bayonet mount, allowing users to switch styles or functionality.
PROCESS
Across ten weeks, the Puck Headphones went through ten CAD iterations, evolving from early sketches to refined, high-fidelity models. Each stage included 3D-printed prototypes to test fit, assembly, and ease of repair. Feedback from peers, tutors, and everyday users shaped improvements, especially around tool-less repair and modular integration. Continue reading to see how Puck was designed from start to finish.
Across ten weeks, the Puck Headphones went through ten CAD iterations, evolving from early sketches to refined, high-fidelity models. Each stage included 3D-printed prototypes to test fit, assembly, and ease of repair. Feedback from peers, tutors, and everyday users shaped improvements, especially around tool-less repair and modular integration. Continue reading to see how Puck was designed from start to finish.
Across ten weeks, the Puck Headphones went through ten CAD iterations, evolving from early sketches to refined, high-fidelity models. Each stage included 3D-printed prototypes to test fit, assembly, and ease of repair. Feedback from peers, tutors, and everyday users shaped improvements, especially around tool-less repair and modular integration. Continue reading to see how Puck was designed from start to finish.
I immersed myself in the world of headphones, researching every detail of the market, and started conceptualising my product. Through online polls, interviews, and academic publications I determined that batteries, hinges, ports, and PCB's are the headphone components that fail the most.
I immersed myself in the world of headphones, researching every detail of the market, and started conceptualising my product. Through online polls, interviews, and academic publications I determined that batteries, hinges, ports, and PCB's are the headphone components that fail the most.
I immersed myself in the world of headphones, researching every detail of the market, and started conceptualising my product. Through online polls, interviews, and academic publications I determined that batteries, hinges, ports, and PCB's are the headphone components that fail the most.
I took CMF queues from brands including Nothing, Leica , and Teenage Engineering, as well as the famous designs of Yves Behar and Dieter Rams.
I took CMF queues from brands including Nothing, Leica , and Teenage Engineering, as well as the famous designs of Yves Behar and Dieter Rams.
I took CMF queues from brands including Nothing, Leica , and Teenage Engineering, as well as the famous designs of Yves Behar and Dieter Rams.
I made 10 complete iterations of the Puck system in SOLIDWORKS, 3D printing each version to critique fitment, asethetics, and functionality. I rigorously tested the repair features, gathering insights from a broad group of user testers.
I made 10 complete iterations of the Puck system in SOLIDWORKS, 3D printing each version to critique fitment, asethetics, and functionality. I rigorously tested the repair features, gathering insights from a broad group of user testers.
I made 10 complete iterations of the Puck system in SOLIDWORKS, 3D printing each version to critique fitment, asethetics, and functionality. I rigorously tested the repair features, gathering insights from a broad group of user testers.
The final design balances structural stability with a clean visual style, while remaining adaptable for scalable manufacturing methods like injection moulding.
Puck challenged me to design beyond aesthetics — to create something genuinely lasting and user-friendly. Prioritising repairability reshaped how I approached CAD, testing, and user feedback. It reinforced the idea that good design empowers users, and that sustainability starts with smart, accessible decisions at the design stage.
The final design balances structural stability with a clean visual style, while remaining adaptable for scalable manufacturing methods like injection moulding.
Puck challenged me to design beyond aesthetics — to create something genuinely lasting and user-friendly. Prioritising repairability reshaped how I approached CAD, testing, and user feedback. It reinforced the idea that good design empowers users, and that sustainability starts with smart, accessible decisions at the design stage.
The final design balances structural stability with a clean visual style, while remaining adaptable for scalable manufacturing methods like injection moulding.
Puck challenged me to design beyond aesthetics — to create something genuinely lasting and user-friendly. Prioritising repairability reshaped how I approached CAD, testing, and user feedback. It reinforced the idea that good design empowers users, and that sustainability starts with smart, accessible decisions at the design stage.