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I mean I have a 3d printer I could prototype but generally 3d prints aren't an end all solution as their porous surfaces are a breeding ground for bacteria. And after some testing I could think of maybe two ways to accomplish this, one with a speaker behind a half circle that fits in like a plug. The downside of this design is you would constantly have to rotate the open portion of the semicircle to be directed towards your ear canal. The other idea is an assembly that fits in as a plug and uses a probe that rests against an area behind your ear to do bone conduction rather than straight audio. This is generally meant to be a stealth or at the least pretty discreet listening system
Well, I don't really have any ideas for implementing the actual headphone portion. But as for the porous nature of 3d prints, I offer 2 separate solutions with wildly different cost points:
A common one is to 3d print a mold for pouring a different material
Three options, two with a similar cost point and one with a different one!