I fixed my AirPods Max headband for pennies after Apple quoted me hundreds

Last month, my original AirPods Max turned five. I bought them in 2021, and they’ve lasted half a decade thus far. That isn’t a long life in the context of wired headphones, but wireless headphones make repairability tricky. There’s added complexity, battery degradation, and parts availability to worry about. It’s no surprise that after five years of regular use, my AirPods Max could use a refresh. I planned to swap out the ear cushions and headband, but that proved to be more expensive than I ever could’ve imagined.

You see, I have a love-hate relationship with Apple’s over-ear headphones. They have real design flaws, from the hefty weight to the uncomfortable headband. The AirPods Max also cancel out airplane cabin noise better to my ears than any pair of ANC headphones I’ve tried, and I love the sound signature. So, I put up with their flaws — until my AirPods Max’s mesh headband completely wore out. An official Apple repair would’ve cost more than half the price of new AirPods Max 2, but I fixed my over-ears with a free 3D print file.

The AirPods Max headband has a $300 problem

Apple designed the AirPods Max to feature premium materials at the expense of comfort. There’s a stainless steel frame, aluminum ear cups, and plush ear cushions. You don’t see wireless headphones made out of this much metal often, and for good reason. Metal is heavy, and headphones that strain your head and neck aren’t ideal. Alas, the AirPods Max weigh 384.8 grams, and the AirPods Max 2 are somehow heavier at 386.2 grams.

The AirPods Max are too heavy, but I’ll admit the mesh headband distributed the weight pretty well out of the box. The problem with mesh is that it’s bound to wear out over time. My pair of AirPods Max became less and less comfortable over time, until one day I couldn’t bear to wear them for 30 minutes. I realized that the mesh headband had become completely saggy, leaving the AirPods Max’s entire 384.8 grams resting on two stainless steel rods. Those rods sat right on my head and made for the most uncomfortable headphone-wearing experience I’ve ever had.

You can see what a saggy AirPods Max mesh headband looks like in the photo below. The headphones’ internal stainless steel frame is resting directly on the headphone stand. This is how a worn-out AirPods Max headband sits on your head, and it’s not pleasant.

You might assume the AirPods Max’s mesh headband is covered by warranty or AppleCare Plus, or at least a cheap repair. The opposite is true. The mesh is built into the headband itself, so you’ll need to replace the entire headband to fix the sagging. Repair options are nonexistent. Worst of all, the AirPods Max headband is actually a large connector that transmits data between the two ear cups. The technology at work makes the AirPods Max headband a pricey replacement part.

Third-party stores like CentralSound claim to have official OEM headbands available for $150. You’ll find replacements available on eBay and similar marketplaces for slightly less, but their authenticity is anyone’s guess. Here’s the kicker: Apple will quote you $300 to repair an AirPods Max headband. It’s often considered cosmetic damage or normal wear and tear, so the limited warranty or AppleCare Plus protection likely won’t help. To make matters worse, Apple won’t sell you the replacement part directly, meaning you’ll be on the hook for parts and labor.

As an AirPods Max owner, I find that $300 quote insulting. The headband isn’t a serialized part and can be replaced in under a minute. Insert a SIM-eject tool into the holes near the top edge of each ear cup (under the ear cushions), and the old headband pops out. Snap the new headband into place, and the AirPods Max are good as new. I don’t know why Apple isn’t selling replacement parts for the headband, or why it is charging so much for what is a simple repair. Regardless, I knew I had to find another alternative.

The only DIY fix that worked cost almost nothing

Once you’ve decided not to buy a replacement headband or pay for an official Apple repair, you have a few DIY options. There are third-party accessories that strap onto the AirPods Max headband to improve comfort, but I didn’t love the added bulk or extra cost. I passed on buying those, and instead tried a strange Reddit tip. I poured boiling-hot water over my AirPods Max headband to help it regain its elasticity. It surprisingly worked, but only for a day or two — the risk wasn’t worth the possible reward, and I wouldn’t recommend it.

Finally, I stumbled upon a 3D print file on Bambu Lab’s MakerWorld community that proved to be the perfect solution. Made by user Spas Makes, this file produces a 3D-printed TPU insert that pops into the top of your AirPods Max headband. TPU, short for thermoplastic polyurethane, is a bendy, stretchy, and flexible plastic material. It’s a softer substance that is better suited to distribute the AirPods Max’s weight on your head than a worn-out mesh headband and a stainless steel frame.

I printed it in about two hours on my tiny Bambu Lab A1 Mini printer, using only 22 grams of filament. That equals just over 2% of a 1,000-gram roll of TPU filament, which costs $22. I did the math and fixed my AirPods Max with less than 50 cents’ worth of 95A TPU filament — when Apple would’ve charged me hundreds.

After printing, the TPU insert slotted neatly into my AirPods Max headband. It served as a buffer between my head and the painful stainless steel rods, with the soft mesh fabric covering the flexible plastic. I could once again wear my AirPods Max for longer listening sessions without experiencing extreme discomfort. In fact, I’d wager that my AirPods Max with the TPU insert feel better than they did with a brand-new mesh headband.

I saved my AirPods Max with 22 grams of filament

The AirPods Max are one of the few Lightning devices I still own, and I’d love nothing more than to upgrade to the AirPods Max 2 with a USB-C port and a fresh headband. However, I couldn’t justify replacing my AirPods Max when the only thing wrong with them was the headband. I also couldn’t bring myself to pay $300 for Apple to swap a simple replacement part. Considering the AirPods Max 2 have the same flaw, this is a problem wearers will face for years.

If you’re in the same boat, consider using a 3D printer to make a DIY headband insert for your AirPods Max. If you don’t own a 3D printer or know someone who does, your local library or community college may be able to help for a small fee. Even if you have to pay for someone to print an insert for you or buy one on Amazon, it beats giving Apple hundreds of dollars. This simple addition gave my AirPods Max a much-needed refresh five years into ownership — and gives them a chance of lasting another five years.