From an engineering standpoint, I missed a lot on the hand I printed (it was a cyborg beast), but actually building one and meeting up with the recipient was just... awesome...
Well we'll see, maybe I make my own design some time..
But for now... *drum rolls*
Project upGrado has started!
Bought some replacement cushions for Beyerdynamic DT770 phones and simply cut some cardboard to a donut shape that fits both the Grado's cups and the cushion's contour, and fixed it with zip ties. Now my guinea-pig SR80e is not only VERY comfortable to wear, but also sounds better than before because the Beyerdynamic cover foam is much better (and thinner) and the over-ear from on-ear conversion puts the sound to your ear better.
Next up is a 3D printed replacement cup that accepts the DT770 cushions in a more stylish and permanent fashion, and will hopefully further increase the sound quality by making it thicker than the original.
Final step will be to integrate an AKG K92 headband (yeah, I actually bought one of these just for the headband...) and have the ultimate headphone for just about 250$. They beat the **** out of pretty much any headphone you compare them to
/edit:
AKG is gonna hate me for buying one of their headphones and only using their cardboard box and the headband
/edit2:
Here's another shot with comparison to the original cushion.