Fathom is hiring for multiple positions across our 11 nationwide sites! To see all open positions, click here.

logo fathom

3D Printed Headphones for the Runway

3D Printed Headphones for the Runway

Monster is the world’s leading manufacturer of high performance cables for audio/video components used in the home, car and office — a widely celebrated product by music lovers, audiophiles, recording studios, sound professionals, musicians, custom-installers and home theater enthusiasts.


The company came to Fathom in need of prototyping six headphones, a new design that would be worn by celebrities and runway models at an event in Paris where Monster would unveil a new brand partnership. Monster required a quick turnaround since the fully finished models would be hand carried on a plane to Europe in eight days.

“I was tasked with a project that was pretty much impossible to pull off, needing six completed models in just eight days for the largest fashion show in Paris,” said Mike Reickerd, Director of Manufacturing and Quality at Monster. “I discovered Fathom on the web on Thursday, had files and NDA’s on Friday, a design review on Saturday and was 3D printing by that afternoon.”

The Fathom team reviewed the CAD model and advised on changes that would maximize 3D printer speed, increase model durability and reduce project complexity in order to meet the quick turnaround requirements. Monster opted to 3D print the main body, CNC machine small accents and flexible headband and finish the model with custom paint. Additional accents were added.


“The very next day we were on a conference call with a machinist, a paint expert and a CAD specialist to coordinate our efforts,” said Tony Slavik, Prototype Studio Manager at Fathom. “Given the short amount of time, the Fathom team advised the customer on necessary changes to the internal design.”

The goal was to maintain all aesthetic features while simplifying the assembly so that most of the model could be 3D printed, sanded and painted — shortening production time without altering design intent.

“With the majority of the assembly 3D printed,” said Slavik, “It was easier to simplify the metal accents. This made the CNC machining of those parts relatively simple so the tight deadline could be met.”

The 3D printed assembly was built on an Objet 500 Connex3 in VeroBlue, an ideal material for models that need to be sanded and painted.

“It’s slightly softer than other Vero materials, making the bodywork faster,” added Slavik. “Plus, the color catches shadows well to show off any flaws that still need more sanding.”

Within days, all models were completed and delivered to the fashion show in Paris on time.

Comprehensive Capabilities for Rapid Manufacturing

At Fathom we offer a unique advantage of speed and agility-our experts help companies go from concept to prototype to manufacturing in ways not previously possible. 

90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day

Get A Quote

30 Second Quotes
Prototype Tool / / As soon as 10 days
10K Parts / / 10 days
Production Tool / / As soon as 3 weeks

Get A Quote

3 & 5 Axis Milling & Turning
(Plastics, Composites and Metals)

Tolerance Accuracy Range
from +/-0.001″ to 0.005″

Get A Quote

Injection Molding Adjacent
without High Costs of Metal Tools

Most Commonly Used for High-Volume
Prototyping & Bridge to Production

Get A Quote

Finishing, Production Painting and Color Matching

Assembling, Including Embedded Electronic
Components, Threaded Inserts, and More

Get A Quote

CAD, DFAM and DFM Services

Apply Methods to Increase Speed
and Decrease Total Cost

Get A Quote

Highly Trained Staff / / Full-Time & Part-Time
Support as Short-Term & Long-Term Strategy

Decrease Downtime with Customizable
Staffing Accelerates Implementation

Get A Quote

Let’s get started.

Fathom is driven by advanced technologies and methods that enhance and accelerate today’s product development and production processes.


Across National
Time Zones

Precision manufacturing
from coast to coast.

1050 Walnut Ridge Drive
Hartland, WI 53029

444 W. 21st St. Ste. 101
Tempe, AZ 85282

46758 Lakeview Blvd
Fremont, CA 94538

7770 Washington St.
Denver, CO 80229

14000 N.W. 58th Court
Miami Lakes, FL 33014

1207 Adams Drive
McHenry, IL 60051

1401 Brummel Ave
Elk Grove, IL 60007

13758 Johnson Street NE
Ham Lake, MN 55304

1920 Slaterville Rd.
Ithaca, NY 14850

401 W. Shore Blvd.
Newark, NY 14513

1513 Sam Bass Rd.
Round Rock, TX 78660

fathom yellow color logo