What Are the Best Aviation Headsets of 2020?
Our look at some popular headsets from budget to premium, with a few interesting outliers, too.
Much of aviation changes slowly, if at all. After all, the most popular models in today's fleet were built 40 or more years ago. It was nearly twice that long ago that the regulatory framework that governs light aviation was riveted in place. But thankfully, since then some things have changed for the better, and headsets are one of them.
It hasn't always been that way. Many of our readers, myself included, began flying before headset use was encouraged. It wasn't that anyone was ignorant of the risks, just that widespread use of headsets wasn't yet a thing. Luckily, though, a couple of pioneers saw the future and dedicated themselves to building headsets that were light enough and comfortable enough to wear for long stretches. Today headsets are more than a curious pilot accessory. They are a preflight checklist item, and not just for the pilot but for everyone on board.
To get there from the earliest headsets, which dispensed as much pain as they did reduce noise, took some time and some doing. The chief advances were the introduction and use of better, more durable, quieter and more form-fitting cushioning materials for both the ear cups and the headband. The design of the headset structure, from headband to ear cups, has advanced in similar, often less-dramatic ways, though a few, including a couple we review here, use a headband design, a steel arch that sits atop the head with pads attached to each end, that is strong and durable but not particularly comfortable.
Today's headsets cut noise in a variety of ways, though the most popular ones use a combination of passive and active noise attenuation, which you can mimic by sticking your ears with your fingers, as most of us do when a particularly loud plane pulls up to the front of the FBO ramp.
The other major advancement in comfort and noise reduction was the introduction more than 25 years ago of active noise-canceling technology, which electronically cuts down on the noise in the outside environment.
Regardless of how it is done, cutting down on noise is critical to pilot health...and performance. Stress and distraction are far more likely to compromise a pilot in a noisy environment. A good headset is a piece of safety equipment, and today's pilots get that.
It goes beyond safety, as well. We can't stress enough the importance of wearing a good headset every time you switch on the mags. General aviation aircraft, especially piston singles and even those that are considered quieter than most, are way too loud for your ears. The Occupational Safety and Health Administration (OSHA) says that damage to your hearing will result from long-term exposure to levels above around 85 dBs For reference, a typical noise level in a legacy Cessna Skylane is around 92 dbs. So while few headset makers discuss the noise reduction specs behind their headsets, you can safely assume that every model in our lineup, if worn correctly, will cut noise to well below that OSHA reference point, which is any headset's most important function.
The other big advances in headset design are in the realm of connectivity. Most of today's models, even budget ones, can connect to your phone or tablet wirelessly.
The headsets in our roundup are of three basic designs, over the ear, on the ear and in the ear. For most light plane flying, the on-the-ear designs are not quiet enough, but for some, not all, twins and light jets, they are just right. So keep that in mind as you peruse our lineup, and be sure to match your mission with the right model.
Clarity Aloft Link
Unlike the Flex, which has gone off the charts minimalist, the Link gives you both Bluetooth and ANR. It also features the companyâs long-running over-the-top design. Itâs hard to call it a headband, because itâs way less structure than any headband youâve seen. Itâs a flexible shielded piece that goes over your head and extends all the way to the ear supports, which are part of the same structure, running from ear to ear. As with the Flex model, the Link has its earpieces (the tips are replaceable, for optimum comfort) on short wires to allow the wearer to get the fit just right without pulling at all. The thing that makes the Link worthy of its name is the power and connectivity box, manufactured by Pilot, that controls the Bluetooth for both phone and tunes. This non-TSOâd headset is super light, at 1.5 ounces, not counting the box.
Features: Lightweight; replaceable foam earplugs; Bluetooth phone/music input; stereo/mono.
Street Price: $795
Lightspeed Zulu 3
The third in a lineup of impressive, lightweight, high-noise reduction models from the pioneering electronic noise reduction maker Lightspeed, the Zulu 3 is everything its remarkable predecessors were and then some. A premium headset at a street price about $250 less than its main competition, the Bose A20, the Lightspeed product offers, in essence, a âbuy three, get the fourth one free deal.â We love this headsetâs sleek looks, the added room inside the ear cups, the slightly restyled shape of the cans that make it even easier to wear for long stretches while making it easier to talk and take a sip of water without breaking the seal. In fact, if you look at the Lightspeed premium headset evolution, the Zulu 3 has essentially taken what few gripes some users had about it and fixed them. In so doing, it has also set itself apart as arguably the best value in aviation headsets and for sure a must-consider alternative when looking for a premium headset, or four.
Features: New contoured ear seals; cables with Kevlar core; Bluetooth for phone and music, automatic shutoff and comm radio priority. Weighs 14.6 oz.
Street Price: $850
Bose A20
Itâs hard to believe, but the bestselling Bose headset has been around for more than 10 years now, with pilots like us loving it and flying with it, a lot. And remember that the A20 replaced a headset, the Aviation Headset X, that was a decade-long industry leader in its own right. Back then, some observers were saying the current product was long in the tooth; despite that, it remained the top-selling aviation headset right up until it was superseded by the new kid in town. And despite the headsetâs continued hot sales, Bose did come out with a new model, the A20, which captured all the mojo of its successor and then some, quickly becoming the premier headset in the market, despite some impressive competition. So is Bose coming out with another new aviation headset for light plane flyers soon? We donât know, but whether it does or doesnât, the A20âlight, supremely comfortable for hours at a time, and with great sound both coming and goingâremains a formidable presence in the market as the most coveted model.
Features: Bluetooth phone and audio; smart audio muting; TSOâd; 45-hour battery life with smart shutoff.
Street Price: $1,095
Bose Proflight Series 2
One thing about pilots: They let you know what they think about things. And when Bose came out with its original Proflight TSO lightweight headset a few years ago, the companyâs customers had a laundry list of complaints, many of them centered on, one, the unwieldy cord, and, two, acoustic anomalies. Fixed and fixed. The Proflight Series 2 has a cable that goes where you tell it to, so you can literally never think about it again, and an updated intercom interface has solved the unwanted electronic noise issues. Plus, itâs even lighter than its predecessor. With the Series 2, Bose has created the product it should have with the first iteration, and pilots are raving about it. Itâs quite the package. The digital ANR shines, and Bose is really good at ANR, in both its consumer and aviation products, so while this TSOâd headset is super light, itâs remarkably quiet as well, though it is intended for quieter aircraft, especially commercial jets. The controls allow you to select the level of ANR in three steps. A third thing that has been much improved over the original is a handy feature that allows you to tap on the ear pad to cut off the ANR to facilitate pilot-to-pilot communications.
Features: Thin, flexible cable; rotating side pads; digital active noise cancellation; silicone ear tips in three sizes; active equalization; adjustable boom mic; electret noise-cancelling mic; tap to talk; quick-release mic and down cable; TSOâd; Bluetooth phone and audio.
Street Price: $1,045Â
Clarity Aloft Flex
Now for something completely different: The Clarity Aloft Flex is an in-ear headset that stands the two-ear cups-and-a-boom mic headset paradigm on its ear. That said, the standard disclaimer is this: Some folks will not warm up to the in-ear experience. But for those who do, Clarity Aloftâs featherweight models canât be beat. The company has been making in-ear headsets for a couple of decades now and has got the idea figured out, and the Flex is arguably the ultimate expression of this design. So light it defies quantification and so quiet it rivals the best of the over-the-ear models, the Flex is a lot of headset for very few ounces. While previous Clarity Aloft models a couple of generations back struggled a little with fit, the Flex feels very solid. Once you have it in place, which you do not with a headband but by hooking wispy but strong pieces that go over the top of your ear, with the earpieces connected with a right-sized wire, thereâs almost zero sense of constraint. The super-light boom extends from one earpiece. Sounds unlikely, but it works great. The Flex, which is TSOâd, does not come with Bluetooth. There is, literally, nowhere to put the works for it.
Features: Lightweight; replaceable foam earplugs; music input; standard GA twin plugs (PJ plugs); TSOâd; no batteries required; includes carrying case, six pairs of medium comply canal tips and lapel clip.
Street Price: $775
David Clark DC One X
The other member of the Big Three in premium aviation headsets for pilots of light planes is the David Clark DC ONE-X, and while the other two most popular products in this space, the Bose A20 and the Lightspeed Zulu 3, are very similar in design and execution, the DC ONE-X is different in a few intriguing ways. For one, itâs super foldable, making it an ideal headset for those who canât or donât want to leave their headsets in the planes, like those of us who rent, fly in a club or, perhaps, instruct. They are also famously rugged. When I first reviewed the then-new DC ONE-X a few years ago, I noted their apparent classic David Clark bombproof design but said the jury was still out on how theyâd hold up in real-world use. The jury is in. They look and work like new after years of on-again, off-again use, getting jammed in my flight bag (inside the soft bag it comes in, of course), taking up about half the room of a Bose A20 or Lightspeed Zulu 3. They're also comfortable, have excellent, though not-industry best, noise cancellation, world-class sound quality and those awesome patented DC green domes.
Features: Hybrid electronic noise cancellation; Bluetooth capability; fail-safe operation; Digital Signal Processing (DSP) Technology; audio mute. TSO'd.
Street Price: $895
David Clark Pro X2
Not for pilots of small, loud GA planes, the PRO-X2 has earcups that sit on the ear as much as around it and are intended for flyers of quieter, twin-engine turbine-powered aircraft. (It would be right at home in a Cirrus Vision Jet, too.) The TSOâd headset shines in the cockpit of commercial airliners or corporate or private jets. Itâs wear-it-all-day light and comfy, and its solid design makes it easy to pop off one earcup for person-to-person communications in the cockpit without the whole headset wandering away in the process. Like the companyâs full-coverage DC ONE-X, the PRO-X2 makes use of David Clarkâs electronic noise-canceling technology to create an ingenious combination of passive and electronic noise attenuation while remaining easy on the noggin for long stretches, a must for commercial pilots who put in long hours.
Features: Automatic gain control; enhanced auto shutoff; hybrid ENC technology for active noise reduction and optimum audio performance; noise-cancelling electret microphone; Bluetooth; compact, multi-function control module; TSOâd.
Street Price: $745
Faro Stealth
Despite its name, this headset has been showing on a lot of pilotsâ radars these days because itâs the answer to the question, can you take a bunch of todayâs best headset technologies, say, in ear seals, headband padding and active noise reduction, add them to a classic design steel band headset and come up with a wearable and quiet alternative to slicker and more expensive models? We just checked out the Faro Stealth and found the answer to be âyes.â Is it just as good as headsets that cost twice as much? Not even close. But it is remarkably comfortable for the price point, and, despite its heft, its electronics are well madeâour phone connected right off the batâand easy to use. The big pads on the ears make it more comfortable and cut the clamping pressure. Beware thoughâif youâre in a tight cockpit, you will bang the ear cup on the side wall from time to time. Still, the headsetâwe tested the passive modelâcuts noise effectively enough for weekend pilots and is easy enough to wear for at least a couple hours or more at a stretch. And with a pricetag south of or around $450 for the active noise-canceling model, thatâs a lot less bang (and rumble) for the buck.
Features: Impressive active noise reduction; Bluetooth and aux input; double-thick ear seals; noise-cancelling electret microphone; stereo audio with dual volume controls.
Street Price: $449
Lightspeed Sierra
Many pilots find it hard to shell out $750 to $1,100 for a nice headset, but the premium models are not premium because of price only. They are better products than budget headsets, and by a lot. So there is a need for a less-expensive but still good-performing headset thatâs comfortable, offers active noise reduction and Bluetooth connectivity, but wonât break the bank. For several years now, the Lightspeed Sierra has been filling that niche nicely. The tradeoffs are substantial. They weigh about a third more than the Zulu 3 model, their ANR is not as effective, and their seal to the outside world isnât as reliable as their excellent premium stablemate. But with a cost savings of around $200, the Sierra offers a rugged, comfortable and feature-rich alternative to higher-priced headsets.
Features: Bluetooth phone and audio; active noise reduction; auto shut-off, 40 hours of battery life; weighs 16 oz. ; stereo/mono switchable, dual volume controls; user pre-sets; custom iPad app.
Street Price: $650
ASA Air Classics
If you spell âbudgetâ with a capital âB,â we get it, and we also get that for folks tight on dough, looking at headsets can be downright panic inducing. For those pilots, ASA has an excellent throw-back model, the aptly named Air Classics, that presents the best of 1980 technology in a rugged and effective way. With its classic steel band over the top and classic plastic ear cups and acoustic foam seals, the Air Classics provides the bare essentials for a headset. And remember that if the goal is to get the noise level down at least several ticks below 85 dBs, this headset will do it, with an advertised and credible 23 dB of reduction. Is it sexy? No. Is it quiet? Kind of. Is it comfortable? Define âcomfortable.â But for a super-low out-the-door price of $130, itâll get the job done with enough dough left over to get you some flight time.
Features: High-density acoustic foam earcups; electret, noise-canceling flex-boom microphone; gold-plated microphone and headphone plugs; stereo/mono capability; large, dual volume adjustment; adjustable headband with thumb screws; foam ear seals.
Street Price: $129
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