Same issue here — Costa Rica, purchased August 2025, barely used.

I purchased 2 units of the WH3024 (Part No. WH3024-DWW, DP/N 0P37G2, manufactured September 2024) through an authorized Dell distributor in Costa Rica. One unit developed the exact same fracture at the headband pivot/hinge — identical location, same stress whitening around the joint, no physical impact or misuse of any kind.

The headset had minimal use (desk use only, a few months). There are no scratches, dents, or any signs of physical impact anywhere on the unit.

When I contacted the local distributor's warranty department, I was told this is "physical damage" and not covered under warranty — the same response you received.

I have escalated the claim directly to Dell and will report back here with the outcome.

The pattern is clear: this is a manufacturing defect, not user damage. The plastic around the pivot shows stress whitening — a known characteristic of internal material fatigue caused during the injection molding process, not from external impact. The fact that 90%+ of units fail at the exact same point confirms this is a structural/design issue in the WH3024.

I strongly encourage Dell to acknowledge this as a known defect and honor warranties accordingly, rather than placing the burden on end users to prove a manufacturing failure.

I have the exact same problem. My headset was relatively new, and it is now completely unusable because it broke in the same place. This is extremely disappointing. This makes me think twice about the quality of Dell accessories. Can anyone suggest a headset with comparable qualities to the WH3024 such as AI Up-Link Noise Cancellation that is comparably priced? Thank you. 

I also had the headset band break in that same location.  Even though I was well within the 3 year warranty period, I was told that this was "customer induced damage".  I am also looking for an alternative to this headset.