On a quiet morning, hardware engineer Ken Pillonel leaned over his workbench, holding a tiny Apple AirPods Pro charging case. Its glossy, seamless shell looked perfect from the outside—but inside was a ticking timer.
The battery would degrade, the Lightning port might fail, and with Apple’s adhesive-heavy design, the only real option for most users was to replace the entire device. Ken wondered: what if this fragile object could be reborn, reimagined as something durable, open, and accessible?
The Problem With Repair
AirPods and their cases have long been criticized by groups like iFixit for being nearly impossible to repair. The batteries are glued in with strong adhesive, and attempting removal can be hazardous, even causing fires during recycling.
As Reuters reported, recycling AirPods is so difficult that large-scale processors struggle to recover usable materials safely. Apple’s approach, while sleek, locks users into a cycle of disposal and repurchase. Each dead charging case becomes e-waste, fueling a system that discourages repair.
Ken’s Bold Redesign
Refusing to accept obsolescence, Ken set out to reverse-engineer the AirPods Pro case. Using 3D scanning tools and calipers, he mapped every millimeter of its design. His mission was simple but radical:
- Replace adhesives with screws
- Enable safe, simple battery swaps
- Provide open-source files for anyone to use
The result was a new case housing, built with nuts and screws instead of glue, making it fully serviceable. Even the adhesive he chose—cyanoacrylate—can be dissolved in acetone, unlike Apple’s nearly permanent green glue.
Open-Source For The World
Ken didn’t just make a prototype and stop there. With this gesture, repairability shifted from a niche hacker’s dream to something anyone could attempt—from a student curious about sustainability to a teacher who simply wants working earbuds again.
The Ripple Effect Of Accessibility (The Crucial Fourth Point)
This is the heart of Ken’s work. It’s not just about screws versus glue—it’s about empowerment. By making his design open-source and accessible, Ken ensures that repairability isn’t limited to professionals or high-end labs.
- Emma, a music teacher, can fix her own AirPods case instead of spending hundreds on a replacement.
- Arif, a student in Bangladesh, can learn hands-on sustainability by repairing his devices instead of discarding them.
- Communities around the world can take part in reducing e-waste and extending the life of technology.
This is where the story turns from one man’s project to a global movement: the democratization of repair.
Media And Community Response
Publications quickly picked up the story.
- Ars Technica highlighted the case’s USB-C port, replaceable battery, and modular design.
- Hackaday praised the practicality of 3D-printed enclosures and simple repairs.
- Gigazine celebrated Ken’s decision to share his project openly rather than commercialize it.
The reaction wasn’t just applause—it was recognition that change is possible, even if it starts with a single engineer in a small workshop.
Beyond AirPods: A Call To Rethink Design
Ken admits that the earbuds themselves remain extremely difficult to repair. Their miniature components, soldered boards, and tight design make modification daunting. Still, he hopes his work inspires broader shifts in consumer electronics.
As he wrote on his website: “If some guy in his apartment can do it, why can’t Apple?” The question lingers in the air like a challenge—one that speaks to the heart of sustainability.
A Future Worth Building
This story isn’t about rejecting innovation or demonizing sleek design. It’s about asking for balance. Technology should be both advanced and enduring, both stylish and sustainable.
By opening his design to the world, Ken didn’t just repair a case—he sparked hope that the future of electronics could be one where users, not glue, hold the power.
Sources:
ARS Technica
The Verge
Gigazine
