TC-200 Professional Call Centre Headset


The TC-200 Call Centre Headset is a professional headset design and manufactured within 1 year from initial brief, to replace their existing ‘rather engineered’ first product, the TC-1. The solution resulted in a more organic and appealing headset without compromising the company’s reputation for robustness, sound quality and reliability but importantly reduced their production costs by 1/3 over the first product by reducing the number of components, creating a novel snap fit boom bezel and simplifying the assembly processes.

The material selected for the main housing (an Acetyl Co-polymer) prevents bacterial growth and is resistant to chemical attack allowing aggressive cleaner agents to thoroughly clean the surfaces as the product if often shared on a hot desk. The clean simple lines also make the product easy to clean.

The ‘fish tail’ pad disperses the load on the side of the head over a greater area and moves the contact point higher, preventing a constant pressure on the soft part of the skull just above the ear which resulted in greater comfort over long periods of use. Fabricated like a tooth brush, the ‘fish tail’ is a ‘two-shot’ moulding with a stiffer material ‘spine’ running inside a more flexible material pad.


TC-200 Render1

TC-200 RenderDetailAbove CAD renders for the complete assembly showing material type, finish and branding position.


The two images below are the mould tools for the main housing inner cover and the boom bezel. This is known as a family tool as it makes three components with each injection.
As the boom bezel has an undercut to the plastic snap edge, to allow for a continuous rotation of the boom microphone, therefore the tool to create this required a collapsible core otherwise the undercut would prevent removal of the moulded part from the tool once cured (cooled).

TC200Tool2The first image shows the tool open where the centre has moved back into the tool body and the 12 segments have shifted inwards (there are two of these – one for a blank bezel without the boom connector) allowing the moulded part to fall from the tool once moulded.

TC200Tool1The second image shows the tool core closed – the position for moulding all three parts. To the top right of the tool face, you can see the slider that creates the ‘hole’ for the boom to be inserted. This is known as ‘side action core’ where additional movement other than just up – down (e.g. open – close) is required.


Sketch visual concepts of the intended design addressing form/aesthetics.


TC200Promo04Promotional image above © C3 Headsets.



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