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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Hello could you send me a picture how to solder a four-pole plug?

Try the link below. Double check everything before you cast! Picking apart the sugru is hard work. I have had a lot of luck by first coating the plug with a thin layer of hot melt glue. This makes it stronger and easier to set in the mold.

Some tips for soldering:

  • Strip with great care - don't damage any of the strands. You'll play for nicks and cuts later with bad connections and broken wires.
  • Each conductor is made of a bundle of enameled wires with a synthetic fiber core. The core and enamel will foul the solder if left in place. Carefully untwist about 3-5mm of wire and core. I use a magnifying glass and a a hobby knife. Cut away the core completely. To remove the enamel, make a large ball of molten solder with your iron by constantly heating it. Dip each tip in the molten solder for a few seconds to burn away the enamel and tin the wires. Do not dwell too long or you will melt the wires and burn off too much insulation. You will know when you have it right as the wires will have a nice shiny coating. If it is at all black you have melted core in the mix.
    Good luck!
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.