How are headphones made?

A headset manufacturer begins with some basic questions: do I want my headphones to be wireless or wired, and do I want them to be low cost or long lasting?These questions decide the components that the headphones will have and what materials will be used in their manufacture.Most headphones are composed of pre-molded plastic, carbon, polymers and metal, with additions such as ear gel cups and protective rubber or for comfort.

All these materials have to be available to the manufacturer and some can be purchased already created by another supplier, such as the gel cups or the wire for the connection of the headphones.These prefabricated pieces are included in the main design of the headphones.

Many of these components will only affect how sound is produced.If a manufacturer creates thicker cables, not only will they last longer, but the sound quality will also improve.If the plug is gold plated, the headphones will cost more, but they will transmit a clearer sound.If the manufacturer decides to add noise cancellation or a damping effect, these will also affect the materials and designs chosen.

Headphone materials and structure decisions

A headset manufacturer begins with some basic questions: do I want my headphones to be wireless or wired, and do I want them to be low cost or long lasting? These questions decide the components that the headphones will have and what materials will be used in their manufacture. Most headphones are composed of pre-molded plastic, carbon, polymers and metal, with additions such as ear gel cups and protective rubber or for comfort.

All these materials have to be available to the manufacturer and some can be purchased already created by another supplier, such as the gel cups or the wire for the connection of the headphones.These prefabricated pieces are included in the main design of the headphones.

Many of these components will only affect how sound is produced. If a manufacturer creates thicker cables, not only will they last longer, but the sound quality will also improve. If the plug is gold plated, the headphones will cost more, but they will transmit a clearer sound. If the manufacturer decides to add noise cancellation or a damping effect, these will also affect the materials and designs chosen.

Sound production systems for headphones

The most important part of the earphone design is the sound producing component. The frame of the headphones will be built around this part. There are several different sound systems that a manufacturer can make. Traditionally, headphones were made with a small dynamic controller, where a magnet is placed in each earphone, creating a small magnetic field where a coil of wire is trapped. The electrical signals are sent through this cable, creating a different magnetic force and the two forces reproduced by each headphone create sound vibrations that are picked up by the ears.

The design becomes more complex if you want better audio quality. Some designs have two magnet coils in each headset, one for bass sounds and one for treble sounds. For more precise control of sound waves, developers can use an alternative membrane method in which a membrane is fixed instead of a single conductor charged with electricity to make it move. Your movements are captured by a mini-amplifier and are thus transformed into the sounds you hear.

There are other systems used to produce sound, but one of the most complicated and exclusive is the balanced design of the armature, which uses the idea of ​​membrane, but adds a revolving magnet within the global magnetic field. This magnet keeps balanced when it is not used, but when it is powered with electricity it pivots and moves the membrane, thus creating the sound.

Additions of the manufacturer and studies

Once the sound system has been created, developers can add peripheral components to perform other tasks. Sometimes it includes a control system that links to the media player, sending signals to the player so that users can control the volume or change the songs with the buttons on their headphones. Those that are Bluetooth require additional components to send and receive wireless signals to compatible devices.

Headsets that have active noise cancellation are connected to complex systems that detect outside noise and generate signals to counteract noise. Manufacturers spend years studying the effects of their insertions, the bone density of listeners, the loss of sound and the binaural patterns so they can create a headset design with minimum distortion and maximum quality.

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