I've had a couple of Bose Aviation X headsets for a number of years.  One headset had chunks of plastic broken out of both yokes (the parts that hold the earcups).  I believe I'm correct in that Bose no longer supports these headsets, and even if they did, they charge a flat fee for repairs that is/was very expensive!  The audio quality of the Bose headsets is unsurpassed, but it is inexcusable that they are so fragile for a $1000+ item!  To add insult to injury, Bose drops support on old headsets as a form of forced obsolescence to induce you to buy the latest/greatest product.

Jon Croke, who produces the Homebuilt HELP video series, recently released a "Tip of the Week" about using 3D printing to very economically produce replacement yokes for the Bose headsets.  I don't have easy access to a 3D printer, but he also mentioned that Ebay replacement yokes were available.  I found a pair of 3D printed yokes, carbon fiber reinforced and with a lifetime guarantee, for less than $40.

I order a pair of these and the quality and strength/durability appears to be excellent!  They look "industrial strength" compared to the original parts and have a nice textured finished on the exterior:

As I removed the original yokes, I gently flexed one of them and it easily cracked:

It took all of 15 minutes to do the repair.  The end result looks great, functions great, and more importantly, appears to be much more durable than the original part:

Thanks to Jon for his great videos and providing alternatives to very expensive repairs - if available at all!

John

N750A