Phitek, a leader in aviation audio solutions, wanted to create an innovative economy class headphone that twists into a flat form for easy stowage. They set out to craft a cost-effective, durable product that enhances passenger comfort while meeting the tough demands of airline use, ensuring travelers could enjoy a better experience even on long flights.

Globex partnered with Phitek to bring their twist headphone concept to life, working against a tight 2-month timeline to develop a near production-ready design. The team refined the industrial design in-house, embedding electrical tracks into the plastic headband to create a robust sliding contact system that ensures comfort and reliable signal transmission, even with the frequent handling and wear typical of economy class environments.

To meet the deadline and showcase the headphone’s potential, Globex also managed the production of trade-show mockups with supply partners. These mockups were designed to look and function like finished products, highlighting the headphone’s award-winning design and functionality for Phitek’s presentations at global aviation events.

Capabilities Used:

• Requirements analysis and concept development

• 3D modeling / CAD design

• Product design and prototyping

• Plastics tooling

• Assembly design

• Vendor management

• Short-run manufacturing

Ultimately, Globex successfully delivered the twist headphone design and trade-show mockups to Phitek, meeting all cost and durability requirements. The innovative headphone, which won Silver at the Best Design Awards 2015, now stands ready to enhance the economy class experience for airline passengers globally.