Make dug this project out of the Sugru Gurus files, showing an ingenious use of the self-curing fixit material.
Sugru user carsonlau writes, "A clumsy seat-mate on an airplane broke the audio plug on my earphones when he was trying to get out of his seat. I was able to remove the existing overmolded strain relief and resolder the connections, but I was left without a strain relief. I used some heat shrink tubing for a while, but was unsatisfied with the appearance."
Thanks to a little open-source love from the manufacturer, Carson downloaded the original CAD file for his earphones’ strain relief from the manufacturer’s website. After printing out the mold on a 3D printer and using olive oil as a mold release, voila! A brand new, perfectly created part to fix his earbuds. Details on each step are available on the post.
This is just the kind of project that shows why having parts information available through manufacturers and some great all-purpose tools and materials like a 3D printer and Sugru make high-quality repair easy for anyone. What parts would you make using these materials? Anything sitting around in drawers waiting to be repaired?