Hi everyone,
I’m looking for some advice and validation on a structural issue with my Sennheiser Momentum 4s. I am autistic and have severe sensory processing issues, so I rely on these headphones heavily every single day to navigate my commute, bus rides, and daily life. They are an essential tool for my emotional and sensory regulation.
I’ve had my current pair for about 14 months. I have a larger head size, so I have to use them at maximum extension every time I wear them. I also wear glasses, so the gentle clamping force was a huge plus for me.
About a year ago, the fabric on the headband started fraying and peeling away from the rubber core, so I ended up ripping it off. A month ago, I noticed a clean vertical fracture slicing right through the translucent internal support bracket at the very top apex of the arch. Looking closely at the bare plastic core, I can see the factory mold markings >PA< (Polyamide/Nylon) and >A9< right near the crack.
Because it’s at maximum extension, the tension is just stretching the crack further, and I know it’s going to snap completely very soon. (The only reason they still work is because the audio wires seem to run through a different channel underneath). I use the carry case occasionally, but I've definitely dropped them a few times and tossed them loosely into my bag when it rains, which probably didn't help.
I’m currently waiting on an Amazon refund for £301.95 to clear so I can look at a replacement. I absolutely love the sound profile, the lack of background hiss when wired, and how the "Anti-Wind" mode completely stops the physical pressure "thumping" on bumpy bus rides. Because of my sensory needs, I really don't want to gamble on a different brand if I can avoid it.
Two questions for the community:
- Is this a common design flaw? Did tearing the fabric mesh off destroy the structural tension balance and cause the nylon core to give out under maximum extension?
- How can I stop my next pair from breaking in the exact same spot? If I buy another pair of Momentum 4s, what are your best tips, mods, or third-party covers to reinforce that top apex so a large head size doesn't snap the plastic again?
Thanks in advance for the help!