Tool/software:
The TPA6120 oscillates easily if trying to drive headphones directly. The fix per the app note is to insert a resistor in series with the output of not less than 10 Ohms but in the data sheet reference circuits shown as 32 Ohms. On large diaphragm dynamic cans, this is not good because you really want to drive them with a low source resistance. Since this is a CFA, can Rfeedback not be set to a much higher value than the 1.5k shown in the data sheet with a concomitant change in Rgain to get more phase margin, and then allow (nearly) direct drive of the headphones using say a small series output inductor + parallel damping resistor? The trade-off would be lower closed loop bandwidth and slower rise/fall times but its worsth it to get the low output impedance drive. A simple formula for this, or some phase margin plots vs Rfeedback would be a welcome addition to the data sheet, or an app note. Assume worst case capacitive loads of <2 nF, but more typically <500pF.