A clumsy seat-mate on an airplane broke the audio plug on my earphones when he was trying to get out of his seat. I was able to remove the existing overmolded strain relief and resolder the connections, but I was left without a strain relief. I used some heat shrink tubing for a while, but was unsatisfied with the appearance.
Carson was able to download the original CAD file for his earphones’ strain relief from the manufacturer’s website and use it to design the mold elements, which were then printed by photopolymer jetting. He used olive oil as a mold release. More details at the link below.
P.S. If you’re in the market for Sugru, please consider buying it through the Maker Shed.