Beats product deconstructionby Will Bond
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This part probably has the highest tooling cost of any of the parts in the headphones, because it requires many cams in order for the part to be released from the mold. Cams allow for parts of the mold to move perpendicular to the parting line. These extra parts have to meet perfectly, in order for the parts to be molded properly. It is easy to tell what direction the two halves of the mold pulled apart from the round dots you can see in the photo above — those are ejector pin marks, from where the part was pushed out of the tool.
these pieces in the headband are made from cast zinc because that ABS parts used for the rest of the product don't provide enough weight, so zinc is used for its density and stiffness to add weight and structural support.
The ear pads are made by a process called punch cutting, which uses a steel die that has been custom designed for the piece. This is pressed on to sheet material at pressures of up to 10 tonnes depending on material punching out a clean cut and finished piece in one move. the punches are cut as efficiently as possible in a process called Lay planning. www.micromec.com
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