Constructing headphones tends to be a long and complicated process, because they are usually made up of no less than 50 parts. However, a new manufacturing process called roll-to-roll is now building headphones that are simple, thin and easy to produce.
The whole process takes place on a single roll of plastic which is then printed/embedded with conductive materials and other technology along the assembly line, much like making circuit boards (albeit much nicer looking). It doesn't require wires nor injection moulding because the parts for the device are already embedded exactly where they need to be. All there is left to do is just to cut out the final shape.
The headphones are only made up of eight parts, and this is all thanks to designer Maxieme Loiseau. The speaker, while only a millimetre thick, reportedly offers quality comparable to regular headphones because its design is based on a piezoelectric cell, which generates sound by using electricity stored in crystalised substances.
Slimmer, sexier headphones with no wires to inadvertently destroy? Sounds like a heavenly future.
[Source : FastCo Design]