Evil J,
Interesting to note you use a Sennheiser. It seems the British manufacturers' traditional dominance of the ATC 'hat' market is under threat from Germany. When I worked in airline engineering, all the pilots preferred the Sennheiser over the Airman 750 so they're obviously a good make. I wouldn't be surprised to see Beyer moving in as well, that's if they haven't done so already. I sympathise with you for the response you received for your suggestions to NATS. I have never worked for NATS but my general work experience shows that 'them upstairs' get p'd off when the folk at the sharp end have the temerity to make a suggestion which might improve things. By the way, may I ask which airfield you work at ?
Last time I was at Newcastle (1994) the ATC gang were using grey lightweight binaural nylon hats. Forget the make but very comfortable and robust. Together with a very Heath Robinson handmike in the VCR and plug-in PTT switches. Custom built stuff definitely has its attractions !