I have a Convoy headband which I’ve messed with a little. Its ok, ya get what ya pay for. I am absolutely 100% satisfied with my Armytek Wizard’s headband thus far. Comfy, firm, holds well, easy to adjust. Extra o-ring strap if you need more security but ya won’t…
I have a couple of ZebraLight headlamps and I like the headbands. The silicone holder is a tight fit, which is good for keeping the light aimed where you want it. It could be inconvenient if you plan on removing and re-installing the light frequently. I’ve heard of folks tearing the ZebraLight silicone but that hasn’t happened to me.
I also own the Armytek Wizard Pro with the newer style headband and the o-ring retainer. It’s ok, but I find the hard plastic mount a bit bulky and uncomfortable after wearing it for a while.
I removed the strap that goes over the top of your head and both stay put just fine for my uses. I keep the headbands loose so they sit high on my forehead rather than farther down to tightly hug it.
I wear headlamps for closeup tasks and hiking. I’d probably need to cinch them tighter if I was running or doing gymnastics.
Depending on your task, you could experiment with wearing the headband loosely around your neck.
Others have developed a way to re-thread the ZebraLight headband to position a layer of fabric between your forehead and the silicone mount. I find it more comfortable this way, but perhaps a bit more fiddly to adjust:
I own 2 skilhunt headmands, they are the three strap as well and seems high quality. i believe they now even release a new holder with a clip, so you don’t have to fiddle the light in and out
i make my own, i use wide bands 35-40mm (as opposed to stock 25mm bands) they hold the light better, but to use them i make my own holders as well, that are wider, also wider base helps keep lights more steady,
some examples below. i make such holders for all headlight i have, i like them much better than silicone ones, i can easy remove the light from there.
I like your custom headbands and holders alpg88. They look very comfortable. I often wear a headlight for over an hour and can see the benefits of your wider band design.