I have used the Astro A40's for around forty or so hours, and usually, I would begin writing a review on a headset after about the thirty-hour mark. I couldn't do this for the A40's, as I felt that every time I used them in the various scenarios that I did, they just got better.
Let's talk about design. Upon opening up the A40's box and plugging them into my PC and immediately jumping into a game of Apex Legends, I noticed the extreme comfort of the fabric earcups. These earcups are.... Legendary, and I need not say more. As for the weight of the headset, it looks lighter than it actually is. Now, this doesn't mean that they feel heavy on your head, but the weight is recognizable.
The customization options this headset provides are fantastic. Even though the Mod-Kit is a further $99 to add that new level of customization, it's a feature that's still there if you want it, and ultimately a really nice touch.
Taking off the headset is an entirely different story. Unfortunately, I have had MAJOR issues taking off the A40's due to their flexibility. Don't get me wrong, the flexibility is great when the headset is on your head, but taking them off the wrong way can give you a shocking amount of anxiety. Let me explain. If you are mid-game, and for whatever reason, you have to get up quickly, most gamers take off their headset with one hand, as their other hand is still on their mouse.
For me, I usually take my headset off with my left hand, but taking the A40's off with JUST your left-hand means that the weight from the right-hand side earcup is lower than the left. This makes the headset twist due to its flexibility, and even a few times, I accidentally slammed my headset down onto my desk. The A40's are a $149 headset, so slamming or twisting of any kind isn't something gamers want to experience. What I had to do to ensure there was no twisting was to make sure I removed the headset from my head with both hands.
Even though the headset does twist, which really isn't nice to look at, it still holds together surprisingly well. The plastic is very strong, and so are the pieces of metal connecting the headset to its comfortable headband.
Microphone design. A big thumbs up to Astro (if you are reading this) for allowing users to change the microphone from one side of the headset to the other. While this might sound like a small feature, it's very thoughtful, and would certainly make the odd user who wants this in a headset very happy.
The cable management of the Astro A40's can be a bit of a nightmare due to how long they are. If you are a PC gamer, I'd recommend investing in some zip ties/velcro ties to tie up the extra cables into a nice bunch. This will stop any accidental tugging from chair movement, arm movement, etc. As for console gamers, depending on how far away you are from your system, you might have some trouble with cable management as there is quite a lot of it.
Overall, the design of the A40's is great. It's minimalistic, comfy, has a lot of customizable options, and does its job very well. The only downside I can really give it is excessive cables, and the fact that the headset feels somewhat flimsy.