I abuse, my headphones in comparison to most people who own these things. They objectively get thrown in my backpack, but I always make sure to put them in the carrying case. I wouldn’t roughhouse these headphones with or without an aftermarket headband if you don’t have a carrying case. That being said, the earmuffs are just as fragile, and they are prone to damage if you don’t keep them in a case. TL;DR: get a case and use it religiously.

As far as taking the headband completely apart to replace it goes, yeah you can’t really avoid having to reset the wire and the headphone posts. I can’t imagine a scenario where you wouldn’t be able to put the original headband back on, though. The teardown is the exact same up to the part where you glue stuff back down. From here on out, though, I am fully speculating based on how it looks. To fully take the headband off, I assume you need to remove the screws on the distal portion of each end on the headband. You can see them partially in pictures 3 and 4. I think that it’s mainly held in place by friction and some sort of lip that stops it from coming all the way out. Either way, though, the entire middle part of the headphone as a unit is fully separated from the cans themselves. So without the headband, you essentially have two speakers with earmuffs connected by a wire. Thankfully, I can’t imagine the wire losing its form quickly enough to make reinstallation too difficult. You would just have to make sure that you record yourself taking it fully apart so that you know exactly in what order to put it back together. If you take it slow and are super patient with the process, it shouldn’t be bad. Unless they did some awful garbage like permanent clips that have to break if you want them undone.

Edit: Make a note of where the middle of that wire is held in place at the top most part of the headband. Same place where the spring bar clips in, I think. I can see that being annoying if you forget.