Case study: High-End Headphones: Audio Foam

The client

High-end audio equipment manufacturer

The challenge

DJ headphones pose a real challenge for manufacturers. Like all headphones, they must be comfortable to wear for extended periods while having high noise-cancelling properties for use in loud nightclubs and home studios.

As such, our client wanted to introduce a range of headphones that were very soft, but also had sound-deadening foam.

Unfortunately, sound-deadening foam is high-density, and therefore heavy, firm and not soft. While effective, it would be uncomfortable to have hard foam pressed against your ears for a long time.

The challenge was to come up with a low-density foam that effectively absorbed sound.

How it worked

Our client explains: “Our decision to appoint Technical Foam Services was based on their knowledge of suitable foam grades available from their global manufacturing partners, as well as their in-house production conversion capability.

Our customer’s DJ headphones were soft and sound-deadening. They fit around the ears, killed external sound and were covered with a permeable vinyl, so they could be wiped clean.

“During the design period, their advice was invaluable, saving us time and enabling is to develop a quality product at a commercial price.”