The headrest mount on my 4-year-old IKEA Jarvfjallet chair snapped and they won't sell you the headrest as a spare part, I'd have to buy the whole 230€ chair again.
Out of spite, I tried to learn 3D modeling and design a replacement part.
Print it facing down to use as few supports as possible.
Reuse the rubber washers on the back side to maintain height adjustability.
A bit of filing might be needed where the mount meets the spine of the chair.
This is a V1, the mount fits and works as expected, but I don't know about durability. Should it break again, I'll update the model accordingly.
The headrest disassembly is a bit hard, not complicated but you have to apply a fair amount of leverage to the locking "external tooth" type wahers that they used to secure the cushion part to the plastic back plate. A long, thick, flat screwdriver should be more than enough to do the job, and even if you break a couple of them in the process it shouldn't be a problem since there's 8 of them.
jarvfjallet_headrest_v10.stl | 165.9KB |