Over-ear headphones' headband or hinge is cracked or broken

Symptoms

• Visible crack in the plastic headband or hinge
• Headphones feel loose, wobbly, or uneven on your head
• One ear cup sits lower than the other
• Creaking or popping sound when adjusting fit

Likely causes

• CommonPlastic fatigue from repeated folding, stretching, or storageThe headband and hinges flex every time headphones are put on, taken off, or folded for storage.
• CommonBeing sat on, stepped on, or droppedPhysical impact is a frequent cause of sudden cracks in the plastic housing.
• PossibleManufacturing defect in the plastic materialSome models have known weak points in specific hinge designs.
• PossibleOverextending the headband beyond its designed range for a large head sizeStretching the adjustable band too far can stress the plastic beyond its limit.
• Less commonUV/heat exposure weakening the plastic over timeLeaving headphones in a hot car or direct sunlight for long periods can make plastic brittle.

What to do

1. Assess the crack's severity: a small hairline crack may be stabilized temporarily, while a full break usually needs a replacement part.
2. Check if the manufacturer or third-party sellers offer a replacement headband or hinge assembly for your specific model.
3. As a temporary fix, a small amount of plastic-specific adhesive or a zip tie/band clamp can stabilize a crack, though this isn't a permanent solution.
4. Avoid over-extending the headband beyond a comfortable fit going forward.
5. Store headphones in a proper case rather than a bag where they can be crushed.
6. If under warranty, contact the manufacturer, since headband cracks are sometimes covered as a defect depending on the cause.

Tools and parts

• Plastic-safe adhesive (for temporary fix)

When to call a pro

If a replacement part isn't available for your specific model or the crack is severe, a repair shop specializing in headphones can sometimes fabricate a fix, or it may be time to replace the headphones.

Safety