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It seems that you have calibration problems with your printer to be honest. I've had a lot of people successfully print these with good flexibility in PLA so maybe the PETG is to blame in this case?

As for sound quality that depends on the drivers you chose. If you go with the ones on our web they sound nice as they were tuned specifically to them: https://www.deskgrown.com/product/armadillo-headphones-kit/