90 degree parametric headphone (TRS) jack mold

by txoof, published

90 degree parametric headphone (TRS) jack mold by txoof Jun 15, 2015
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Got a broken headphone jack? Cut it off, solder on a good one and use this customizable mold to create a new end.


Sugru works great for casting ends!

  1. Customize, print and sand the mold for a good fit
  2. Apply some soapy water to the mold and roughly mold out your jack with sugru.
  3. Press the rough mold into the two halves. Use 2 or 3 bolts to ensure it all lines up properly.
  4. Use a clamp to press the mold firmly together.
  5. Gently open the mold and remove the casting immediately. DO NOT CURE IN THE MOLD. See the notes below.

I had only limited success with allowing the sugru to cure IN the mold. I don't think it can out-gas enough to properly cure. I have since made several more casts of this type using the soapy water

The variable names aren't my finest, but are well documented in the .SCAD file with a nice ASCII drawing. Download it and things will be much more clear.

The DF MarkDown that Thingiverse uses doesn't have a way of escaping 'special characters' so I can't reproduce the drawings here.

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Oct 8, 2016 - Modified Oct 8, 2016

You can use thermo glue stick instead sugru. That works too.

Thanks! I hope it works out for you!

You should get a medal for this.